Ford - Expedition 4wd - Workshop Manual - 1999 - 1999

Factory Workshop Manual Make Ford Model Expedition 4wd Engine and year V8-4.6L SOHC VIN W (1999) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) P0500 - P0504: Testing and Inspection P0500 ( P 0500 ) For diagnosis of P0500 refer to the system experiencing the problem. Computers and Control Systems or Transmission Control System Refer to pinpoint test DP1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed/Transfer Case Speed Sensors For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Transfer Case Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) > Page 9 4 Of 5 For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Windshield Wiper Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) > Page 10 Part 4 Of 5 For complete Windshield Wiper diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) P0720 - P0724: Testing and Inspection P0720 ( P 0720 ) Manual Transmission (M.T.) For diagnosis of P0720 refer to chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 16 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0720 refer to chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 17 5 Of 7 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 18 P0720 - P0724: Testing and Inspection P0721 ( P 0721 ) Manual Transmission (M.T.) For diagnosis of P0721 refer to chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 19 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0721 refer to chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 20 7 Of 7 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1830 - P1834, ( P1831 P1832 P1833 1830 1831 1832 1833 1834 ) > System Information > System Diagnosis > P1834 P1830 - P1834: Testing and Inspection P1834 P1834 is an information code (there is no testing for this code). Code Description: Transmission Transfer Case Differential Lock-Up Solenoid Short Circuit to Battery. Refer to wiring diagrams to diagnose this circuit, See: Transmission and Drivetrain/Transfer Case/Diagrams For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 32 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 33 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 34 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 38 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 41 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 42 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 43 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Locations Multifunction Electronic Control Module: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Locations > Page 47 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 50 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 51 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 53 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 55 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Multifunction Electronic Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 57 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 58 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 59 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Multifunction Electronic Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Multifunction Electronic Control Module: Electrical Diagrams Diagram 59-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Diagram 59-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Diagram 59-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Diagram 59-4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Diagram 59-5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 71 Multifunction Electronic Control Module: Description and Operation The multi function modules consist of the following: ^ Generic Electronic Module (GEM) The Generic Electronic Module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. ^ Heated backlite/mirror. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 72 Multifunction Electronic Control Module: Testing and Inspection For further information regarding the Generic Electronic Module (GEM), please refer to the system controlled by it: The GEM controls the following features: ^ Wiper Control Module. ^ Audible Warning Device Control Module. ^ Interior Lighting Module. ^ Power Window Control Module. ^ Transfer Case Control Module. ^ Heated Glass Control Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 73 Multifunction Electronic Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION ^ Prior to removal of the module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM) electrical connectors from the (B) GEM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 74 6. Remove the screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications Remote Anti-Theft Personality Module Nuts 62 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 78 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 79 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 80 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the remote anti-theft personality module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: The antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the NGS Tester into the new module. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications Remote Anti-Theft Personality Module Nuts 62 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 85 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 86 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 87 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the remote anti-theft personality module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: The antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the NGS Tester into the new module. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay ALL LOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 92 The All Lock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 93 Power Door Lock Relay: Locations All Unlock Relay ALL UNLOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 94 The All Unlock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 95 Power Door Lock Relay: Locations Driver Unlock Relay DRIVER UNLOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 96 The Driver Unlock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay Power Door Lock Relay: Testing and Inspection All Lock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 99 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 100 Power Door Lock Relay: Testing and Inspection All Unlock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 101 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 102 Power Door Lock Relay: Testing and Inspection Driver's Door Unlock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 103 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Service and Repair Power Mirror Control Module: Service and Repair DRIVER SEAT MODULE (DSM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module Power Seat Control Module: Diagrams Driver's Seat Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 111 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 112 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 113 Power Seat Control Module: Diagrams Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 114 Power Seat Control Module: Description and Operation The power driver seat and power outside rear view mirrors are controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM system consists of the following components. ^ Driver seat module. ^ Driver memory seat switch. ^ Memory mirror switch. ^ Memory set switch. ^ Front vertical seat motor. ^ Rear vertical seat motor. ^ Driver horizontal memory mirror. ^ LH heated memory mirror. ^ RH heated memory mirror. ^ Remote entry key fob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Power Seat Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 117 Power Seat Control Module: Service and Repair Heated Seat Module REMOVAL 1. Remove the power seat track. 2. Disconnect the electrical connectors. 3. Remove the heated seat module. ^ Release the clip. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 118 Power Seat Control Module: Service and Repair Seat Module REMOVAL 1. Remove the power seat track. 2. Remove the seat module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the roof opening panel. 2. Disconnect the battery ground cable. 3. Remove the access cover. 4. Slide the roof opening panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations The 4WABS relay is located in the battery junction box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 132 Electronic Brake Control Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 133 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 134 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the ABS module. 4. Remove the anti-lock brake control module. 1. Remove the screws. 2. Remove the anti-lock brake control module. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 135 1. CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Relay > Page 141 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 144 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 145 Blower Motor Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 146 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 150 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 151 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 152 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 153 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 158 Control Module HVAC: Diagrams Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the Electronic Automatic Temperature Control (EATC) module tells the A/C bower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: ^ Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. ^ Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 161 Control Module HVAC: Description and Operation Electronic Climate Control Module The electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: ^ 11 push buttons ^ a blower speed override thumbwheel for manual input ^ a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) ^ an On-Board Diagnostic (OBD) feature to supply the technician with DTCs. These DTCs direct the technician to the inoperative component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Remove the kickpad. 3. Disengage the aspirator hose from the bracket. NOTE: Part shown out of vehicle position. 4. Disengage the blower motor speed control mounting bracket from the instrument panel. 5. Disconnect the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 164 6. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 165 Control Module HVAC: Service and Repair Electronic Climate Control Module WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the control switch connector. 4. Remove the climate control head. 1 Remove the screws. 2 Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 166 5. Disconnect the climate control head. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 167 Control Module HVAC: Service and Repair Illumination Bulbs REMOVAL 1. Remove the Control assembly. 2. Unsnap the bezel and pivot it open. ^ To replace the general illumination bulbs, unscrew the lamp holder and remove the bulb. ^ To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. NOTE: Place the module upside down on a non-marring surface. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 171 System Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 172 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation Audible Warning Device Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 177 Audible Warning Device Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 186 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 187 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 188 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 194 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 195 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 196 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 205 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 211 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Page 212 Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Saver Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 218 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 219 Battery Saver Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 220 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 221 Battery Saver Relay: Description and Operation The following components are controlled by the battery saver relay: - front map lamp assembly - Front door courtesy lamp - Generic electronic module (GEM) - Glove box lamp assembly - Central security module - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay - Illuminated vanity mirrors (Navigator only) The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, or in the sleep mode, (relay coil is de-energized). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 222 Battery Saver Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 223 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Testing and Inspection Courtesy Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Testing and Inspection > Page 227 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 231 The Daytime Running Lamp Relay 1 and 2 are located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 Daytime Running Lamp Relay: Testing and Inspection DRL Relay #1 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 234 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 235 Daytime Running Lamp Relay: Testing and Inspection DRL Relay #2 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 236 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 240 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 241 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 242 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations NOTE: The Autolamp Module and the Headlamp Control Module are the same component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations > Page 246 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 250 Headlamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 251 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 255 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 256 Horn Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 257 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation Interior Lighting Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation > Page 261 Interior Lighting Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 265 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 269 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 270 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Trailer Lighting Relay: Testing and Inspection Trailer Tow Running Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 275 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 276 Trailer Lighting Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 277 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 282 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 286 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay Power Distribution Relay: Locations Trailer Tow Reversing Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 291 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 292 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 293 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 294 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 295 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 296 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 302 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 303 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 304 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 305 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 306 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 307 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 308 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 309 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 310 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 321 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 322 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 323 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 329 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 330 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 335 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 336 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 337 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 342 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 348 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 349 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 354 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 355 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 358 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 359 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 361 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 363 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 365 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 366 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 367 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Engine Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 376 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 377 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 378 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 385 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 390 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 391 Fuel Pump Relay: Description and Operation The Fuel Pump relay: - engages the fuel pump when energized by the powertrain control module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 392 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 393 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 400 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 405 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module (RCM) Bracket Bolts ......................................................................................................................................... 12 Nm (9 Lb-Ft) Weld Nut Repair Screw (8 mm) ................................................................................................ ................................................................... 12 Nm (9 Lb-Ft) Grounding Screw (6 mm) ...................... ....................................................................................................................................................... 12 Nm (9 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 411 Air Bag Control Module: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - The tightening torque of the air bag restraint control module retaining bolts is critical for proper system operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 412 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not repaired separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned OFF and then ON), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash a two-digit lamp fault code (LFC). The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the data link connector (DLC), using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and a system fault is detected, the RCM will signal the GEM to activate the audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 413 Air Bag Control Module: Service and Repair REMOVAL WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the scuff plate. 3. Remove the kick panel. 4. Open the glove compartment past its stop. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 414 5. Remove the glove compartment. 1 Remove the three screws. 2 Remove the glove compartment. 6. Disconnect the Restraint Control Module (RCM) electrical connector. 1 Disengage the RCM electrical connector locking clip. 2 Disconnect the RCM electrical connector. 7. Remove the RCM with bracket. 1 Remove the four retaining bolts. 2 Remove the RCM with bracket. NOTE: Upper RCM bracket retaining screws are accessed through the glove compartment opening. INSTALLATION WARNING: The tightening torque of the air bag restraint control module retaining bolts is critical for proper system operation. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 415 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Terminal Nuts ........................................................................................................................ 5-11 N.m (45-97 Lb-In) Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (62-79 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (44-99 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission Starter Relay: Description and Operation Automatic Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The digital transmission range sensor prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission > Page 422 Starter Relay: Description and Operation Manual Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The clutch pedal position switch prevents starter motor engagement unless the clutch pedal is pressed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 423 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3 .Disconnect the starter motor solenoid relay switch wires and cables. Disconnect the engine control sensor wiring terminal. - Remove the starter motor solenoid relay switch terminal nuts. - Remove the wiring. 4. Remove the starter motor solenoid relay switch. - Remove the bolts. - Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 424 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module > Page 431 Steering Control Module: Diagrams With Air Suspension Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations The air suspension compressor relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 436 Compressor/Pump Relay: Description and Operation A solid state relay is used in the air suspension system for compressor control. The relay incorporates a custom power Metal Oxide Semi-Conductor Field Effect Transistor (MOSFET) and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the air suspension control module. The compressor solid state relay is energized by the air suspension control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 445 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 446 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 456 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 457 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 462 Suspension Control Module: Description and Operation NOTE: The 4WAS control module is also used for the RAS system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. NOTE: The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performed. A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay) and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing the vehicle and related components. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 463 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1 Disconnect the electrical connectors. 2 Remove the air suspension control module and bracket assembly. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. NOTE: Ale air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 474 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 475 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 481 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 482 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 483 Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 484 Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay The Torque On Demand Relay is located behind center of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 489 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 490 Four Wheel Drive Selector Relay: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Description and Operation Heated Glass Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Description and Operation > Page 495 Heated Glass Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 499 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 500 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 501 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Description and Operation Power Window Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Description and Operation > Page 505 Power Window Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > One Touch Down Relay Power Window Relay: Locations One Touch Down Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > One Touch Down Relay > Page 510 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > One Touch Down Relay > Page 511 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay Power Window Relay: Testing and Inspection One Touch Down Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 514 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 515 Power Window Relay: Testing and Inspection Vent Window/Roof Opening Panel Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 516 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Description and Operation Windshield Washer Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Description and Operation > Page 521 Windshield Washer Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 526 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 527 Windshield Washer Relay: Locations Rear Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 528 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay Windshield Washer Relay: Testing and Inspection Front Washer Pump Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 531 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 532 Windshield Washer Relay: Testing and Inspection Rear Washer Pump Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 533 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 537 Wiper Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay Wiper Relay: Locations Rear Wiper Up/Down Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 542 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 543 Wiper Relay: Locations Wiper High/Low Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 544 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 545 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 546 Wiper Relay: Locations Wiper Run/Park Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 547 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 548 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay Wiper Relay: Testing and Inspection Rear Wiper Down Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 551 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 552 Wiper Relay: Testing and Inspection Rear Wiper Up Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 553 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 554 Wiper Relay: Testing and Inspection Wiper High/Low Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 555 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 556 Wiper Relay: Testing and Inspection Wiper Run/Park Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 557 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Power Door Lock Switch > Page 564 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 567 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 568 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 569 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 573 Power Mirror Switch: Testing and Inspection Component Testing Procedure (part 1 Of 2) Component Testing Procedure (part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 574 Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Seat Regulator Control Switch Screws 9-26 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch Power Seat Switch: Diagrams Driver's Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 580 Power Seat Switch: Diagrams Heated Seat Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 581 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch Power Seat Switch: Testing and Inspection Driver's Seat Control Switch With Memory Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 584 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 585 Without Memory Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 586 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 587 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 588 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 589 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 590 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 591 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 592 Power Seat Switch: Service and Repair NOTE: Driver side shown, passenger side similar. REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1. Remove the screw. 2. Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 593 5. Remove the pin-type retainer on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1. Remove the screws. 2. Disconnect the seat regulator control switch. NOTE: If equipped with heated seats, disconnect the switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 594 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ If equipped with heated seats, connect the switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Page 598 Seat Memory Switch: Testing and Inspection Remove the memory set switch. Memory Set Switch Measure the resistance between the following indicated terminals while pressing the requested switches. Switch Terminals Memory Switch 1 6 and 4 Memory Switch 2 6 and 3 Memory Set Switch 6 and 1 The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling pinpoint test. Switch Terminals Memory Switch LED 8 and 9 NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Remote Release To Instrument Panel Bolts .............................................................................................................................................. 2.1-2.9 Nm (18.7-25.8 inch lbs.) Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 9 ft.lb Front ABS Sensor Wire Bracket Bolt 62-80 in.lb Rear Anti-Lock Brake Sensor Bolt 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Removal 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front anti-lock brake sensor bolts and the (B) front anti-lock brake sensor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 617 Wheel Speed Sensor: Service and Repair Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1. Disconnect the rear anti-lock brake sensor electrical connector. 2. Remove the bolt. 3. Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removed procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 623 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 624 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water Temperature Sensor 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 628 Temperature Sensor (Gauge): Service and Repair Removal 1. Partially drain the engine cooling system. 2. On 4.6L engines, disconnect the connector and remove the water temperature indicator sender unit. 3. On 5.4L engines, disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. ^ Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 638 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 639 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 640 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 641 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 642 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 643 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 644 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 645 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 646 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 647 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 648 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 649 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 650 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 651 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 652 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 653 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 656 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 657 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 663 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Deactivator Switch: Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 668 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Deactivator Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 678 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 679 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 680 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 681 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 682 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 683 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 684 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 685 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 686 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 687 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 688 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 689 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 690 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 691 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 692 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 693 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 694 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 695 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 696 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 700 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 701 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 702 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 703 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Deactivator Switch: All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 708 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Deactivator Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Page 713 Deactivator Switch: Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-15 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 716 Deactivator Switch: Service and Repair Deactivator Switch REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running, water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 730 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 731 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch 9-11 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 736 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 742 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Sensor Bracket Bolt 9 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 746 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: ^ is located in front of the A/C condenser core near the center of the vehicle. ^ contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the Electronic Automatic Temperature Control (EATC) module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 747 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Remove the pin-type retainers and remove the radiator sight shield. 2. Disconnect the connector. 3. Remove the bolt and remove the ambient air temperature sensor panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 752 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 753 Blower Motor Switch: Diagrams Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Description and Operation Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: ^ A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. ^ An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. ^ The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. ^ The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Description and Operation > Page 757 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. Disconnect the Control switch connector. 3. Remove the steering column cover panel. 4. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Description and Operation > Page 758 5. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the LH instrument panel finish panel. 6. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 7. Remove the screw. 8. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications Pressure Cut Off Switch 6.8-13.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 763 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Pressure Cut-Off Switch Opens 2896 kPa Approximately A/C Pressure Cut-off Switch Closes 1724 kPa Approximately A/C Cycling Switch Close Maximum 324 kPa A/C Cycling Switch Open Minimum 152 kPa Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. ^ A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. ^ This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. ^ When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. ^ It is not necessary to recover the refrigerant system to remove the A/C pressure cut-off switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 766 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). ^ The contacts close when the suction pressure rises to 276-324kPa (40-47 psi). ^ When the A/C cycling switch contacts close, the A/C clutch field coil is energized. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to recover the refrigerant system to remove the A/C cycling switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the junction block splash shield. 3. Disconnect the cable ends. 4. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 5. Disconnect the A/C cycling pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 769 6. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Carry out the refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 770 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. 1 Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: ^ is located on the top of the instrument panel. ^ contains a photovoltaic diode that is sensitive to light. ^ has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 774 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Fry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair > Page 782 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch 1. Remove the self-locking pin. 2. Remove the spacer 3. Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 798 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 799 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 801 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 802 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 803 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 804 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 805 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 806 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 807 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 809 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 818 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 819 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 820 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 821 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 822 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 824 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 825 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 826 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 830 Hazard Warning Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 831 Hazard Warning Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 832 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 836 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 837 Headlamp Dimmer Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 838 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 839 Headlamp Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 840 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Main Light Switch Headlamp Switch: Diagrams Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Main Light Switch > Page 845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Main Light Switch > Page 846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 847 Headlamp Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 848 Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 849 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 850 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 851 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1. Pull the headlamp switch from the instrument panel. 2. Disconnect the electrical connectors INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL AND INSTALLATION NOTE: The steering wheel pad horn switch is part of the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate the interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 861 Turn Signal Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 864 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 865 Turn Signal Switch: Diagnostic Trouble Code Descriptions GEM Diagnostic Trouble Code Index Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 866 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 867 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 868 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 869 Part 5 Of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 870 Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 871 Turn Signal Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 872 Turn Signal Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 873 diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures GEM Diagnostic Trouble Code Index Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 874 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 875 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 876 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 877 Part 5 Of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 878 Part 1 Of 2 Part 2 Of 2 Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 879 Test A: No Communication With The Module-GEM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 880 Test A1 - A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 881 Test A3 - A4 Test A5 Test B: Unable To Enter Self-Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 882 Test B1 Test C: The Ignition Switch Is Inoperative Test C1 Test D: No Power In ACC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 883 Test D1 Test E: No Power In RUN Test E1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 884 Test E1 - E2 Test F: No Power In START Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 885 Test F1 - F2 Component Tests and General Diagnostics Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 886 Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 887 Pinout Values and Diagnostic Parameters Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 888 Part 1 Of 3 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 889 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 890 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 891 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 892 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 903 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 904 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 910 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 911 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 912 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 913 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 914 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 915 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 919 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 923 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 924 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 928 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 929 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 930 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation The fuel tank pressure sensor: ^ monitors the fuel tank pressure. ^ communicates the fuel tank pressure reading to the PCM during the OBD II leak test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the intake air temperature sensor electrical connector. 3. Remove the Intake Air Temperature (IAT) sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 940 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 945 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 946 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 947 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 948 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 949 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 950 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 951 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 952 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 953 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 954 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 955 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 956 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 957 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 958 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 959 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 960 Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 963 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 967 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 968 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 969 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 970 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 971 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 973 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 974 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 975 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 976 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 977 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 978 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 979 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 980 Oxygen Sensor: Service and Repair Oxygen Sensor Wrench SPECIAL SERVICE TOOLS REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector. 4. Use the special tool to remove the Heated Oxygen Sensor (HO2S). INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 981 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 991 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 992 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 993 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 994 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 995 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1027 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1028 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1034 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1035 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1036 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1037 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1038 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1039 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Service and Repair Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector. 4. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Remove the bolts. 2 Remove the (IFS) switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1050 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1054 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1055 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1056 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1062 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1063 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1064 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1065 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1066 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1067 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1070 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1071 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1072 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1076 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws ........................................................................................................................ ......................................................... 12 Nm (9 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1081 Impact Sensor: Service Precautions WARNING: - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1082 Impact Sensor: Service and Repair REMOVAL WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Navigator is shown, Expedition is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator air deflector. 1 Remove the push clips. 2 Remove the radiator air deflector. 3. Disconnect the front crash sensor electrical connector (RH shown, LH similar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1083 4. Remove the front crash sensor. 1 Remove the screws. 2 Remove the air bag sensor. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The CPP switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1093 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1094 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1095 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1096 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1097 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1098 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1101 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1102 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1103 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Neutral Safety Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair Steering Column Position Sensor: Service and Repair Removal 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1 Remove the steering column lower bearing spring. 2 Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Page 1115 2. Install the shock absorber electronic steering sensor. 1 Position the shock absorber electronic steering sensor. 2 Install the screws. 3 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 1121 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 1122 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the air suspension control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce) to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a usable range of 80 mm (3 inch) compared to total suspension travel of 200-250 mm (8-10 inch) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 inch) of travel at the height sensor. The front height sensor upper socket is attached to the frame bracket at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 1123 Ride Height Sensor: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1 Disconnect the electrical connector. 2 Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1130 Suspension Mode Switch: Description and Operation The air suspension switch supplies power to the air suspension control module. Without the air suspension control module receiving this power, the 4-wheel air suspension system is inoperative and will not react when the vehicle is raised or lowered. If the air suspension is disabled by turning off the air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the RUN position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1131 Suspension Mode Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1132 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 1138 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1142 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1143 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1144 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1145 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1146 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 1152 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 1153 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 1160 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 1161 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1176 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering column opening cover. NOTICE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. 4. Remove the instrument panel finish panel. 1. Remove the panel bolts. 2. Remove the instrument panel finish panel. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1177 6. Remove the rear window defrost switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 1182 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 1183 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 1184 Power Window Switch: Diagrams Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1185 Power Window Switch: Description and Operation The window regulator control switch: - is located on each door trim panel. - may be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - includes a "double detent" feature. - can manually lower the driver side window when the master control is depressed halfway (first detent). - will completely lower the driver side window when the master control is fully depressed and then released (second detent). - can lock out passenger front and rear control switches. The rear quarter glass regulator control switches: - Are located in the overhead console. - May be used to open and close the RH or LH rear quarter windows. - Stop the rear quarter glass in any position when released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front Power Window Switch: Testing and Inspection Left Front Component Testing Procedure (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1188 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1189 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1190 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1191 Power Window Switch: Testing and Inspection Rear Power Window Control Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1192 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1193 Power Window Switch: Testing and Inspection Right Front Power Window Switch Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 1194 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1199 Windshield Washer Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1200 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1201 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1202 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1206 Wiper Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1207 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1208 Wiper Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1209 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1215 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1216 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1217 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1218 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1219 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1220 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1221 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1222 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1223 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1224 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1225 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1226 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1227 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1228 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1229 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1230 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1231 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1232 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1233 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1234 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1235 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1236 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1237 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1238 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1239 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1240 Ford Expedition 4wd Workshop Manual 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Comprehensive Noise/Vibration/Harshness Procedure > Page 1271 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1272 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1273 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1274 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1275 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1276 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1277 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1278 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1279 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1280 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1281 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1282 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1283 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1284 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1285 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1286 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1287 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1288 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1289 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1290 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1291 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1292 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1293 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1294 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1295 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1296 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1297 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1299 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1301 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1302 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1303 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1304 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1305 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1306 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1307 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1308 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1309 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1310 Alignment: Specifications BASE SUSPENSION ALIGNMENT Caster LH ........................................................................................................................................................ ....................................................... 5.1° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.6° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.2° ± 0.7° RH ............................................................................. ................................................................................................................................ -0.2° ± 0.7° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.15° RH ............................................................................. .......................................................................................................................................... 0.15° Total/Split ............................................................................................................................................. ................................................. -0.30° ± 0.25° AIR SUSPENSION ALIGNMENT (TRIM POSITION) Caster LH ........................................................................................................................................................ ....................................................... 5.0° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.5° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.4° ± 0.4° RH ............................................................................. ................................................................................................................................ -0.4° ± 0.4° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.10° RH ............................................................................. .......................................................................................................................................... 0.10° Total/Split ............................................................................................................................................. ................................................. -0.20° ± 0.25° RIDE HEIGHT Rear Curb Ride Height: Without Air Suspension .................................................................................................................................................... 218-242 mm (8.6-9.5 inch) With Air Suspension ......................................................................................................................................................... 168-178 mm (6.6-7.0 inch) Vehicle Lean Specifications Max. Allowable Variance, Front ...................................................................................................................................................... 16 mm (5/8 inch) Max. Allowable Variance, Rear ....................................................................................................................................................... 19 mm (3/4 inch) Ride Height Measurement Original Components Base Suspension ............................................................................................................................................................ 102-132 mm (4.02-5.20 inch) Air Suspension Ignition Off (Kneel Position) ................................................................................................................... 60-87 mm (2.36-3.42 inch) Ride Height, Original Components Base Suspension ............................................................................................................................................................ 107-113 mm (4.21-4.44 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Ride Height, New Components Base Suspension ............................................................................................................................................................ 122-128 mm (4.80-5.04 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Rear Vehicle Height [a] ................................................................................................................................................. 144.8-148.8 mm (5.7-5.8 inches) [a] From Bottom Of Frame To Rear Jounce Bumper Bolt Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1311 Alignment: Locations Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1312 Alignment: Description and Operation Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1313 The three basic alignment angles are camber, caster and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications are static settings with the vehicle unloaded. CAMBER Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1314 CASTER Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). TOE Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Wheel Track Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1315 WHEEL TRACK By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking DOGTRACKING Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the upper suspension arm nuts to a point where the joints are snug. 2. NOTE: A pry bar can be used between the front suspension upper arm and the frame pocket to aid in moving the arm. To increase caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension upper arm outboard and move the rear of the front suspension upper arm inboard. 2 To increase camber, move the front suspension upper arm outboard equally. 3. To decrease caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension upper arm inboard and move the rear of the front suspension upper arm outboard. 2 To decrease camber, move the front suspension on upper arm inboard equally. 4. NOTE: Each increment of the notches on the frame pocket represents 0.3°. Set the caster and camber to specifications. If a caster increase of 0.9° is required, move the front of the front suspension upper arm outboard by 3 notches and move the rear of the front suspension upper arm inboard by 3 notches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1318 5. Tighten the upper suspension arm nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1319 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings. 4. Hold the tie rod end while loosening the toe set jam nuts. 5. Rotate the front wheel spindle tie rod adjusting sleeve to desired position. 6. NOTE: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie rod threads must be cleaned and lubricated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1320 Tighten the toe set jam nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1326 Fuel Pressure Test Port: Description and Operation The Fuel Pressure Relief valve: ^ is used to inspect and relieve fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1327 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1335 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) Outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1346 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1347 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Description and Operation Ignition Cable: Description and Operation The spark plug wires carry high voltage pulses from the ignition coil to the spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Description and Operation > Page 1355 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. To install. reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1360 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1361 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1362 Spark Plug: Description and Operation The spark plug. ^ change the high voltage pulse from the ignition coil into a spark which ignites the fuel and air mixture. ^ are different for the LH and RH side of the engine. ^ originally equipped on the vehicle have a Platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1363 Spark Plug: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Remove the spark plugs. NOTE: Remove any foreign materials from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1364 5. Inspect for carbon fouling ^ Look for black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with a incorrect heat range, dirty air cleaner, too rich fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating identified by a white or light gray-brown spots and white bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with a incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1365 9. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1369 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1370 Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1377 Drive Belt: Description and Operation The accessory drive consists of the: ^ drive belt ^ generator pulley ^ power steering pump pulley ^ crankshaft pulley ^ A/C clutch pulley ^ belt idler pulley ^ drive belt tensioner ^ water pump pulley The accessory drive: ^ has a single serpentine drive belt ^ has an automatic drive belt tensioner ^ does not require adjustment Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 2. Inspect the drive belt for chunking, fraying and wear. 3. Check the drive belt for correct routing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1380 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1381 Drive Belt: Component Tests and General Diagnostics Belt Tensioner NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Replace components as required. ^ Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck the drive belt tracking. ^ Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter NOTE: Tensioner is shown in free-state position against arm travel stops. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1382 Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: ^ If the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. ^ If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be replaced if no apparent damage has occurred. ^ NOTE: The drive belt tensioner arm should rotate freely without binding. ^ If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, replace the drive belt. ^ If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1383 Drive Belt: Service and Repair Removal 1. Rotate the drive belt tensioner clockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1389 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) Outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 11-12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1412 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1413 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1419 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1420 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1421 Heater Hose: Specifications Hose Clamp 2-3 Nm Front Auxiliary Heater Line Brackets 8 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1422 Heater Hose: Description and Operation Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1423 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line The auxiliary lines are two-piece tubes that are secured to the underbody of the vehicle. New auxiliary line kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line Heater Hose: Service and Repair Front Auxiliary Heater Outlet and Inlet Line REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Loosen the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Move the front fender splash shield to access the lines. 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1426 8. Disconnect the heater outlet line from the outlet hose coupling. 9. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. 10. Cut the heater outlet line where it crosses under the frame. 11. Cut the heater outlet line near the front wheel well opening. 12. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1427 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1428 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line NOTE: The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater outlet line. ^ Install the end with the blue tape over the flame. 2. Connect the heater outlet line peanut fitting. 1 Connect the fitting. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Install the end with the red tape over the frame. ^ Install the end with the yellow tape between the frame and the body vertical flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1429 NOTE: View shown with fender skirt removed for clarity. 4. Connect the heater water outlet line to the heater water outlet line. 1 Connect the fitting. 2 Loosely install the nut. 5. Install the heater water outlet line to the heater water outlet line. ^ Install the line through the wheel opening. NOTE: Fender skirt removed for clarity. 6. Connect the heater water outlet line to the heater water outlet line. 1 Connect the fitting. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1430 7. Tighten the three peanut fittings. 8. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION Verify that clearance exists between the frame and the lines to prevent component damage. - Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 9. Connect the heater water outlet line to the engine heater outlet hose coupling. 10. Install the bolts, the pin-type retainers and the front fender splash shield. 11. Install the wheel and tire assembly. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1431 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retailer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1432 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESR-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1433 Heater Hose: Service and Repair Rear Auxiliary Heater Inlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1434 9. Remove the our me bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 12. Cut the heater inlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1435 13. Cut the heater inlet line near the rear crossmember. 14. Cut the heater inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1436 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1437 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the green tape over the rear axle between the frame crossmember and the body. 2. Connect the heater inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape between the frame crossmember and the floor pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1438 4. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the red tape between the frame and the body. 6. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. ^ Install the end with the green tape through the floor opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1439 8. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1440 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1441 Heater Hose: Service and Repair Rear Auxiliary Heater Outlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1442 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 12. Cut the heater outlet line near the grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1443 13. Cut the heater outlet line near the rear cross member. 14. Cut the heater outlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1444 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1445 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape over the axle between the frame and the body. 2. Connect the heater outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the red tape between the frame and the floor pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1446 4. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. 1 Remove RH rear wheel and tire. 2 Install the end with blue tape between the frame and the body. 6. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. ^ Install the end with the hose through the floor opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1447 8. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nuts. 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1448 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater outlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1449 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Disconnect the heater core hose couplings. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 1450 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Page 1451 Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Line Bracket Nuts 6.8-9.2 Nm A/C Evaporator to Expansion Valve Lines 12.7-17.3 Nm Outline Line to Auxiliary Evaporator Case Line 8 Nm Refrigerant Lines To Expansion Valve 12.7-17.3 Nm Front Auxiliary Heater Line Brackets 8 Nm Front Auxiliary A/C Line Bracket 8 Nm Peanut Fitting Expansion Valve Refrigerant Lines 8 Nm Peanut Fitting Rear Heater lines 8 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1455 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: ^ The upstream side contains low pressure refrigerant gas. ^ The downstream side contains high pressure refrigerant gas. ^ An integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. ^ The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without recovering the A/C system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line Hose/Line HVAC: Service and Repair A/C Hose/Line REMOVAL 1. Recover the refrigerant. 2. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 3. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 4. Remove the tube bracket nut. 5. Remove the suction accumulator drier bracket clamp bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1458 6. Remove the evaporator to condenser tube. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1459 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Condenser To Evaporator Line REMOVAL 1. Recover the refrigerant. 2. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 3. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 4. Remove the tube bracket nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1460 5. Remove the suction accumulator drier bracket clamp bolt. 6. Remove the evaporator to condenser tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1461 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Front Auxiliary Evaporator Outlet and Inlet Line REMOVAL NOTE: The 5/8 inch front auxiliary evaporator outlet line is shown, the 3/8 inch front auxiliary evaporator inlet line is similar. 1. Recover the refrigerant from the system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the front fender splash shield. 6. Remove the three line bracket retaining nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1462 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 8. Disconnect the 5/8 inch auxiliary outlet line from the suction side of the A/C manifold and tube assembly. 1 Remove the nut. 2 Disconnect the line. 9. Disconnect the front auxiliary outlet line from the rear auxiliary line. 1 Remove the nut. 2 Disconnect the line. 10. Remove the front auxiliary evaporator outlet line. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1463 1. Install the front auxiliary evaporator outlet line. 2. Connect the front auxiliary outlet line to the rear auxiliary line. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting securely into the torque retention bracket. 3. Connect the front auxiliary outlet line to the suction side of the A/C manifold and tube assembly. 1 Connect the line. 2 Install the nut. 4. Install the line brackets. 1 Position the bracket. 2 Install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1464 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 5. Install the bolts, the pin-type retainers and the front fender splash shield. 6. Lower the vehicle. 7. Turn on the air suspension switch, if equipped. 8. Evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Rear Auxiliary Evaporator Inlet Line REMOVAL 1. Recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1465 8. Remove the four line bracket retaining nuts. 9. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 11. Cut the 3/8 inch evaporator inlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1466 12. Cut the 3/8 inch evaporator inlet line near the rear crossmember. 13. Cut the 3/8 inch evaporator inlet line forward of the rear wheel opening. 14. Cut the 3/8 inch evaporator inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: Lay out new lines in vehicle position to assist in installation. 1. Install the inlet line. ^ Install the end with the hose over the rear axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1467 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1468 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line NOTE: The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 2. Connect the inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. 3. Install the inlet line. ^ Starting from the rear of the vehicle, insert the end with the orange tape between the frame and the body. 4. Connect the inlet line to the inlet line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1469 1 Connect the inlet lines. 2 Loosely install the nut. 5. Install the inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the yellow tape between the frame and the body. 6. Connect the inlet line to the inlet line. ^ Connect the fitting and loosely install the nut. 7. Install the inlet line. ^ Install the end without tape through the floor. 8. Connect the inlet line to the inlet line. 1 Connect the me. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1470 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Connect the inlet line to the auxiliary evaporator case line. 14. Install the grommet seal and retainer. NOTE: Make sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Install the quarter trim access panel. 16. Evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging 17. Install the spare tire. Rear Auxiliary Evaporator Outlet Line REMOVAL NOTE: Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1471 1. Recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front nuts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1472 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the 5/8 inch outlet line peanut fitting that is located outboard of the side rail. 1 Remove the nut. 2 Disconnect the line. 12. Cut the 5/8 inch evaporator cutlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1473 13. Cut tile 5/8 inch evaporator outlet line near the rear crossmember. 14. Cut the 5/8 inch evaporator outlet line forward of the rear wheel opening. 15. Cut the 5/8 inch evaporator outlet line between the frame and the muffler heat shield. 16. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1474 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1475 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the outlet line over the frame. ^ Install the end with violet tape between the frame and the body. 2. Connect the outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. 3. Install the outlet line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1476 ^ Starting from the rear of the vehicle install the end with the violet tape over the frame crossmember and between the main member and the muffler heat shield. 4. Correct the outlet line peanut fitting to the outlet line. 1 Connect the outlet lines. 2 Loosely install the nut. 5. Install the outlet line. ^ Starting from the rear of the vehicle, install the end with the yellow tape between the frame and the muffler heat shield. 6. Connect the outlet line peanut fitting to the outlet line. ^ Connect the fitting and loosely install the nut. 7. Install the outlet line. 1 Remove the RH rear wheel and tire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1477 2 Install the end with the orange tape between tie frame and the body through the rear wheel opening. 8. Connect the outlet line peanut fitting to the outlet line. ^ Connect the fitting and loosely install the nut. 9. Install the outlet line. ^ Install the end of the tube with no tape through the floor. 10. Connect the outlet line peanut fitting to outlet line. ^ Connect the fitting and loosely install the nut. 11. Tighten the five peanut fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 1478 12. Install the line brackets. 1 Position tile bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 13. Install the muffler heat shield. 1 Position the shield 2 Install the nuts. 14. Lower the vehicle. 15. Turn the air suspension switch on, if equipped. 16. Connect the outlet line to the auxiliary evaporator case line. 17. Install the grommet seal and retainer. NOTE: Maker sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 18. Install the quarter trim access panel. 19. Evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging 20. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1479 Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Pressure Hose Fitting ........................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ........................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose Power Steering Line/Hose: Service and Repair Low Pressure Hose Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering low pressure hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering low pressure hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1485 Power Steering Line/Hose: Service and Repair Pressure Hose Special Tool(s) Removal 1. Prepare the vehicle for power steering pressure hose removal. 1 Remove the fan and shroud. 2 Remove the drive belt. 2. Disconnect the power steering pressure hose. Drain the power steering system. 3. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1486 4. Disconnect and remove the power steering pressure hose. Installation 1. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 2. Route the power steering pressure hose in the vehicle. Connect the power steering pressure hose. 3. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Install the power steering pump pulley Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1487 4. Connect the power steering pressure hose 5. Restore the vehicle to operating condition. 1 Install the drive belt. 2 Install the fan and shroud. 3 Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1488 Power Steering Line/Hose: Service and Repair Pump Reservoir Hose Removal 1. Prepare the vehicle for power steering reservoir pump hose removal. 1 Remove the fan and shroud. 2 Remove the drive belt. 2. Remove the three bolts. 3. Disconnect the power steering reservoir pump hose. Drain the power steering system. 4. Remove the nuts and belt deflector. 5. Remove the two bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1489 6. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 7. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 8. Remove the bolt. 9. Lower the vehicle. 10. Position the power steering pump forward. 11. Disconnect and remove the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1490 Installation 1. Route the power steering reservoir pump hose in the vehicle. Connect the power steering reservoir pump hose. 2. Position the power steering pump. 3. Loosely install the bolts. 4. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1491 5. Install the bolt. 6. Connect the EVO power steering control valve actuator electrical connector. 7. Lower the vehicle. 8. Tighten the bolts. 9. Install the belt deflector and nuts. 10. Connect the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1492 11. Position the power steering pump reservoir. Install the three bolts. 12. Restore the vehicle to operating condition. 1 Install the drive belt. 2 Install the fan and shroud. 3 Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 1493 Power Steering Line/Hose: Service and Repair Return Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering return hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering return hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1494 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) Removal 1. Drain the engine cooling system. 2. Remove inlet side of Air Cleaner (ACL). 3. Disconnect the lower radiator hose from the oil filter adapter. 4. Disconnect the lower radiator hose from the degas bottle. 5. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. Raise and support the vehicle. 6. If equipped with engine oil cooler, disconnect the lower radiator hose connections from the oil cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1499 7. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect and remove the lower radiator hose. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. The lower radiator hose does not require rotation for installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1500 Radiator Hose: Service and Repair Radiator Hoses (Upper) Removal 1. Partially drain the engine cooling system. 2. Remove the upper radiator hose. 1 Release the hose clamps and slide away from the hose ends. 2 Remove the upper radiator hose. Installation 1. NOTE: Make sure that the upper radiator hose is seated in the upper hose support bracket. Install the upper radiator hose. 1 Position the upper radiator hose. 2 Compress and position the hose clamps. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1505 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: - Eye Contact - rinse eyes thoroughly with water. - Skin Contact - wash skin with soap and water. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1510 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications 1 row radiator and standard heater 20.5 L 2 row radiator and standard heater 21.8 L 1 row radiator and aux. rear heater 21.7 L 2 row radiator and aux. rear heater 23.5 L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1513 Coolant: Fluid Type Specifications Coolant Type ....................................................................................................................................... ................................ Ford Premium Engine Coolant Ford Specification................................................................................................................................. .........................................................ESE-M97B44-A Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe Engine Coolant (orange in color). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1514 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1519 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1520 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Capacity Including Cooler A/T Fluid .............................................................................................................................................. ......................................................... 13.2L (13.9 Qt) Total Fill Capacity A/T Fluid 4R70W ................................................................................................................................................. ......................................................... 13.1L (13.9 Qt) 4R100 .................................................................................................................................................. ............................................................. 15L (15.9 Qt) NOTE: Approximate - make final inspection with dipstick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1523 Fluid - A/T: Fluid Type Specifications NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Automatic (4R70W) ............................................................................................................................. ..................................................... MERCON V ATF Automatic (4R100) ............................................................................................................................................................. MERCON or MERCON V ATF Automatic (E40D) ............................................................................................................................................................. MERCON or MERCON V ATF NOTE: Automatic transmissions requiring MERCON V should only be serviced with MERCON V, or fluid from a container that is specified as a dual usage fluid: MERCON/MERCON V. NOTE: Automatic transmissions requiring MERCON can not be serviced with MERCON, MERCON V, or dual usage fluids labeled MERCON/MERCON V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1524 Fluid - A/T: Diagrams PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1525 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1526 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1527 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1528 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1529 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1530 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1531 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1532 LINE/SRV PRESSURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1533 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1534 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1535 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1536 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1537 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1538 4TH GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1539 MANUAL 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1540 MANUAL 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1541 MANUAL 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1542 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1543 Fluid - A/T: Testing and Inspection FLUID LEVEL CHECK CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the do not drive mark or internal failure could result. NOTE: If vehicle has been operated for an extended period of time at highway speeds, city traffic, hot weather, or pulling a trailer, the fluid needs to cool down to obtain an accurate reading. NOTE: The fluid level reading on the indicator will differ from operating and ambient temperatures. The correct reading should be within the normal operating temperature range. Under normal circumstances, the fluid level should be checked during normal maintenance. If the transmission starts to slip, shift slowly, or has signs of fluid leaking, the fluid level should be checked. 1. With the transmission in (P) PARK, the engine at idle, foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the range selector lever in the PARK position. 2. Wipe the fluid level indicator cap and remove the indicator. 3. Wipe the indicator with a clean cloth. 4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating temperature range. HIGH FLUID LEVEL A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated, refer to Transmission Fluid Drain and Refill. LOW FLUID LEVEL A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. ADDING FLUID CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid. FLUID CONDITION CHECK 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor. 3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter, coolers, and cooler lines. Perform diagnostic checks and adjustments; refer to the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1544 Diagnosis by Symptom Index. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1545 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid. ^ Normal Maintenance ^ No recommended changes ^ Special Operating Conditions, Change fluid at 48,000 km (30,000 miles) 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. Disconnect the battery ground cable. 2. Raise and support vehicle on hoist. 3. Place a drain pan under the transmission fluid pan 4. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. ^ Replace transmission fluid pan gasket as necessary. 6. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1546 7. Remove the torque converter drain plug and drain the torque converter. ^ Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A) transmission fluid pan, (B)transmission fluid pan gasket and (C) magnet. 9. Flush the fluid cooler and fluid cooler lines. 10. Flush the torque converter. Installation 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1547 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan 5. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 6. Install bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1548 7. Lower the vehicle. 8. Connect the battery ground cable. 9. NOTE: When filling a dry transmission and torque converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. ^ Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent fluid meeting FORD specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service Precautions Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal capacity. This may cause fluid foaming and transmission damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential .................................................................................................................................. ................................................................. 1.8 - 2.0L Rear Differential ................................................................................................................................... .................................................................. 2.9 - 3.1L Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1556 Fluid - Differential: Fluid Type Specifications Front Axle ............................................................................................................................................ ............................................................. SAE 75W-90 Rear Axle ............................................................................................................................................. .......................................... SAE 75W-140 Synthetic Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1557 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity Transfer Case Fluid ............................................................................................................................. ........................................................................... 1.9L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1562 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid ............................................................................................................................. ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1563 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1564 Fluid - Transfer Case: Service and Repair 1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: The fluid level must be just below the fill plug. Remove the fill plug and check the fluid level. ^ If the fluid is below the proper level, fill the transfer case with Motorcraft MERCON Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON equivalent. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1569 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1570 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1571 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1572 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1575 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 NOTE: Refer to TSB# 02-1-9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1576 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1581 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1582 Power Steering Fluid: Specifications Power Steering Fluid Type .................................................................................................................................................... Premium Power Steering Fluid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1583 Power Steering Fluid: Service Precautions CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may result. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1588 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1589 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1590 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1591 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications System Capacity R-134a 62 oz (US) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1594 Refrigerant: Fluid Type Specifications Refrigerant............................................................................................................................................ ........................................................................R134a Ford Part Number ................................................................................................................................ ..................................................................... YN-19 Ford Specification ................................................................................................................................ ................................................... WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Without Auxiliary .................................................................................................................................. .......................................................... 266 ml (9 oz) With Auxiliary ...................................................... ......................................................................................................................................... 414 ml (14 oz) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1599 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil...................................................................................................................................... ...Polyalkylene Glycol (PAG) Oil (R-134a Systems) Ford Part Number ........................................................................................................................................................... F7AZ-19589-AD (MC-YN-12C) Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding Brake Bleeding: Service and Repair Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has be en drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1604 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1605 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for IS minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1606 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with c lean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1607 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding cooperation. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1608 5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1609 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: This procedure must be performed if the 4 Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been installed new. NOTE: One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal. NOTE: Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. NOTE: Add recommended brake fluid as necessary throughout the procedure. 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. Have an assistant pump the brake pedal and then hold film pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 1610 5. A Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. 6. NOTE: Go to the help menu in the NGS Tester. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the NGS instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the NGS service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1615 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1638 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1639 Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1640 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1645 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1646 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1647 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1648 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1649 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1650 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1651 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1659 Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 1665 Fuse Block: Locations Central Junction Box (Instrument Panel) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 1666 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 1667 The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Fuse Block: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1692 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1693 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1694 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1695 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1696 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 1700 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 1705 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED indicator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation WARNING ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. ^ The jacking point is a raised boss located on the front suspension lower arm. The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. The rear jacking points are located on the rear axle. CAUTION: Never use the differential housing as a lifting point. Lifting WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1716 HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1717 Vehicle Lifting: Service and Repair JACKING WARNING ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. ^ The jacking point is a raised boss located on the front suspension lower arm. The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. The rear jacking points are located on the rear axle. CAUTION: Never use the differential housing as a lifting point. Lifting Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1718 WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications TORQUE SPECIFICATIONS Spare Tire Carrier Bolts ............................................................................................................................................................. 23-32 Nm (17-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 1723 Spare Tire: Service and Repair SPARE TIRE CARRIER REMOVAL 1. Lower the spare tire. 1 Insert the drive end of the jack handle through the opening left of the license plate. 2 Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. 1 Slide the retainer through the center of the spare tire assembly. 2 Remove the spare tire assembly. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Remove the spare tire carrier. 1 Remove the bolts. 2 Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 1724 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1729 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1730 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1731 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1732 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1733 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1734 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1735 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1736 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1737 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1738 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1739 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1740 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1741 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1742 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1743 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1744 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1745 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1746 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1747 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1748 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1749 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1750 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1751 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1752 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1753 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1754 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1755 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1756 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1757 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1758 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1759 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1760 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1761 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1762 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1763 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1764 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1765 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1766 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1767 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1768 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1769 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1770 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1771 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1772 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1773 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1774 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1775 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1776 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1777 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1778 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1779 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1780 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1782 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1783 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1784 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1785 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1786 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1787 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1788 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1789 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1790 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1791 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1792 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1793 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1794 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1795 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1796 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1797 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1798 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1799 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1801 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1802 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1803 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1804 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1805 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1806 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1807 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1809 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1811 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1812 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1818 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1819 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1820 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1821 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1823 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1824 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1825 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1826 Wheels: Specifications GENERAL SPECIFICATIONS Cast Aluminum .................................................................................................................................... ................................................................ 17 x 7.5J Steel .................................................................... .................................................................................................................................................... 16 x 7J Styled Aluminum ............................................................................................................................. ....................................................................... 16 x 7J Styled Argent Steel ......................................... ........................................................................................................................................................ 16 x 7J Wheel Offset ................................................................................................................................ ........................................................................... 14 mm Wheel Rim Runout (Radial Or Lateral) ........................................................................................................................................... 1.12 mm (0.044 inch) Maximum Balance Weight [a] .......................................................................................... ............................................................................. 170 g (6 oz.) [a] Total Of Inner And Outer Wheel Flanges Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information Wheels: Technician Safety Information WARNING: Never run the engine with one wheel off the ground, for example, when changing a tire. The wheel resting on the ground could cause the vehicle to move. WARNING: The tire and wheel must always be properly matched. It is very important to determine the size of each component before any assembly operations commence. Do not mount a 16-inch tire on a 16.5-inch wheel. Failure to adhere to these instructions can result in an explosive separation and cause serious bodily injury or death. Do not mount a 16.5 inch tire on a 16 inch wheel. The tire can come off without warning. WARNING: Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure these products have not been used. WARNING: Use only wheels and lug nuts that have been designed for the correct model year Ford trucks. Aftermarket wheels or lug nuts may not fit or function properly, and can cause personal injury or damage the vehicle. WARNING: Always wear safety goggles or a face shield when performing any work with tire and wheel assemblies. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information > Page 1829 Wheels: Vehicle Damage Warnings WARNING: Retighten the lug nuts at 800 km (500 miles) after any wheel change or any time the lug nuts are loosened. WARNING: Failure to retighten lug nuts at the mileage specified can allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specification ESR-M5B194-B . CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core . Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Page 1830 Wheels: Description and Operation WARNING: Do not mix different types of tires such as radial, bias, or bias-belted, on the same vehicle except in emergencies (temporary spare usage). Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. Replacement tires should follow the recommended: tire sizes. - speed rating. - load range. - radial construction type. Use of any over tire size or type may seriously affect: ride. - handling - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - wheel bearing life. - brake cooling. Wheels need to be replaced when: bent. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. A two-piece lug nut is used, containing the nut and a washer. Wheel and tire assemblies are attached by five noncentering lug nuts. When balancing wheels and tires, use T-type balancing weights. The spare tire is mounted under the frame. The valve stem should be on the top side of the tire to reduce the possibility of accidental valve stem air leakage. To equalize tire wear, rotate the tires periodically. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks Wheels: Service and Repair Leaks 1. CAUTION: Do not attempt to repair aluminum wheels that leak air. If repairs are made to the wheel, the structural integrity of the wheel can be lost. Replace any aluminum wheel that leaks air. 2. Replace or repair any wheel that leaks air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 1833 Wheels: Service and Repair Replacements Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting of the wheel or the surface of the wheel hub or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface and wheel centering O-ring. 2. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the tire and wheel assembly. 1 Inspect the wheel centering O-ring. Replace if damaged. 2 Position the tire and wheel assembly. 3 Install the lug nuts, hand-tight, then lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 1834 3. Tighten the lug nuts in sequence. 4. Install the center cap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1839 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1840 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1841 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1842 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1843 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1844 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1845 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1846 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1847 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1848 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1849 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1850 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1851 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1852 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1853 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1854 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1855 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1856 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1857 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1858 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1859 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1860 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1861 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1862 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1863 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1864 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1865 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1866 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1867 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1868 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1869 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1870 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1871 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1872 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1873 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1874 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1875 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1876 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1877 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1878 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1879 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1881 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1882 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1883 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1884 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1885 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1886 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1887 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1888 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1889 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1890 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1891 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1892 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1893 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1894 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1895 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1896 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1897 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1898 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1899 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1900 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1901 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1902 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1903 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1904 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1905 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1906 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1907 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1908 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1909 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1910 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1911 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1912 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1913 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1914 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1915 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1916 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1917 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1918 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1919 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1920 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1922 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1923 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1924 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1925 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1926 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1927 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1928 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1929 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1930 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1931 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1932 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1933 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear Wheel Bearing: Specifications 8.8 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear > Page 1936 Wheel Bearing: Specifications 9.75 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1937 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear Wheel Bearing: Service and Repair 8.8 Inch Ring Gear Removal 1. Remove the axle shafts. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 1940 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 1941 Wheel Bearing: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear axle bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 1942 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 1945 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft Hub Nut 188 - 254 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA99V099000 > Apr > 00 > Recall 99V099000: Wheel Lug Retorqueing Wheel Fastener: Recalls Recall 99V099000: Wheel Lug Retorqueing Vehicle Description: Sport utility vehicles equipped with four-wheel-drive (4x4), 17" chrome steel wheels. The clamp load can be lost on the wheel lugs due to insufficient wheel contact area with the hub. In some cases, the contact area can deform, resulting in a loss of lug nut torque. Loss of lug nut torque can cause vibration or separation of a wheel and tire from the vehicle. Dealers will re-torque the wheel lugs to proper specifications and also install a label that specifies that the wheel lugs be torqued to 110 lb-ft any time the wheel is removed. Owner notification began May 7, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque Technical Service Bulletin # 99S12 Date: 990501 Recall - Chrome Steel Wheel Lug Nut Torque 99512 SAFETY RECALL Certain 1999 Expedition and Navigator 4 x 4 Vehicles with Chrome Steel Wheels Lug Nut Torque ^ Recall/Service Program Information ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1962 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1963 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement could result in a civil penalty of up to $1,100 per vehicle. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator and Expedition owners qualify for the "Special Customer Handling Procedure. Before calling vehicle owners, review Attachment IV to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Promptly correct other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION Enter claims using DWE. See ACESII Manual for claims preparation and submission procedures. To claim for the "Special Customer Handling", follow the instructions on Attachment IV. Attachment II - Labor and Parts Information REFUNDS ^ Ford is offering a full refund to customers who paid for vehicle repairs that were caused by loose wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1964 ^ See ACESII manual for refund procedures and information. LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An initial supply of warning labels was included with the original Safety Recall Bulletin, 99S12. Additional warning labels can be obtained free of charge by calling 1-800-325-5621. Attachment III - Technical Information OVERVIEW Some vehicles affected by this recall are not equipped with chrome steel wheels. In performing this recall, inspect each affected vehicle to determine if it is equipped with chrome steel wheels. If the vehicle is equipped with chrome steel wheels, perform the service procedure shown. If the vehicle is not equipped with chrome steel wheels, it should be returned promptly to the customer. INSPECTION PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1965 1. Visually inspect the wheels on the vehicle and compare to Figure 1. If the wheels on the vehicle are: ^ identical to either of those shown in Figure 1, proceed with the service procedure. ^ different from those shown in Figure 1, the vehicle does not require service. Return the vehicle to the customer without delay. SERVICE PROCEDURES CAUTION: POWER TOOLS OR TORQUE STICKS MUST NOT BE USED. ONLY USE A CLICK-TYPE OR DIAL-TYPE TORQUE WRENCH TO PERFORM THIS OPERATION NOTE: Tighten lug nuts using the standard STAR pattern as specified in the appropriate service manual. CAUTION: THE LUG NUTS MUST BE COOL ENOUGH TO TOUCH BEFORE PERFORMING THIS PROCEDURE. IF THIS PROCEDURE IS PERFORMED ON LUG NUTS THAT ARE NOT COOL ENOUGH TO TOUCH, INACCURATE TORQUE READINGS AND WHEEL CLAMP LOADS MAY RESULT. 1. Remove the center caps from each wheel. 2. Check for minimum installed wheel lug nut torque as follows: A. Set the torque wrench to 88 Nm (65 lb-ft). B. Attempt to tighten all lug nuts. ^ If any lug nut starts to rotate on the stud before the minimum torque of 88 Nm (65 lb-ft) is reached, call the Recall Hotline at 1-800-325-5621 for further instruction. ^ If all of the lug nuts on each wheel do NOT rotate before the torque wrench reaches 88 Nm (65 lb-ft), proceed with step 3. 3. Tighten all wheel lug nuts to 149 Nm (110 lb-ft) following the standard STAR pattern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1966 4. Using alcohol and a clean shop cloth, thoroughly clean the center portion of the wheels in the locations shown in Figures 2 and 3. 5. For U.S. vehicles, apply one (English) label to each wheel at the location shown. See Figure 2. 6. For Canadian vehicles, apply two (2) labels (one English and one French) to each wheel in the locations shown. See Figure 3. 7. Reinstall the center caps on each wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1967 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1968 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1969 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1970 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA99V099000 > Apr > 00 > Recall 99V099000: Wheel Lug Retorqueing Wheel Fastener: All Technical Service Bulletins Recall 99V099000: Wheel Lug Retorqueing Vehicle Description: Sport utility vehicles equipped with four-wheel-drive (4x4), 17" chrome steel wheels. The clamp load can be lost on the wheel lugs due to insufficient wheel contact area with the hub. In some cases, the contact area can deform, resulting in a loss of lug nut torque. Loss of lug nut torque can cause vibration or separation of a wheel and tire from the vehicle. Dealers will re-torque the wheel lugs to proper specifications and also install a label that specifies that the wheel lugs be torqued to 110 lb-ft any time the wheel is removed. Owner notification began May 7, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque Technical Service Bulletin # 99S12 Date: 990501 Recall - Chrome Steel Wheel Lug Nut Torque 99512 SAFETY RECALL Certain 1999 Expedition and Navigator 4 x 4 Vehicles with Chrome Steel Wheels Lug Nut Torque ^ Recall/Service Program Information ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1980 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1981 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement could result in a civil penalty of up to $1,100 per vehicle. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator and Expedition owners qualify for the "Special Customer Handling Procedure. Before calling vehicle owners, review Attachment IV to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Promptly correct other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION Enter claims using DWE. See ACESII Manual for claims preparation and submission procedures. To claim for the "Special Customer Handling", follow the instructions on Attachment IV. Attachment II - Labor and Parts Information REFUNDS ^ Ford is offering a full refund to customers who paid for vehicle repairs that were caused by loose wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1982 ^ See ACESII manual for refund procedures and information. LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An initial supply of warning labels was included with the original Safety Recall Bulletin, 99S12. Additional warning labels can be obtained free of charge by calling 1-800-325-5621. Attachment III - Technical Information OVERVIEW Some vehicles affected by this recall are not equipped with chrome steel wheels. In performing this recall, inspect each affected vehicle to determine if it is equipped with chrome steel wheels. If the vehicle is equipped with chrome steel wheels, perform the service procedure shown. If the vehicle is not equipped with chrome steel wheels, it should be returned promptly to the customer. INSPECTION PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1983 1. Visually inspect the wheels on the vehicle and compare to Figure 1. If the wheels on the vehicle are: ^ identical to either of those shown in Figure 1, proceed with the service procedure. ^ different from those shown in Figure 1, the vehicle does not require service. Return the vehicle to the customer without delay. SERVICE PROCEDURES CAUTION: POWER TOOLS OR TORQUE STICKS MUST NOT BE USED. ONLY USE A CLICK-TYPE OR DIAL-TYPE TORQUE WRENCH TO PERFORM THIS OPERATION NOTE: Tighten lug nuts using the standard STAR pattern as specified in the appropriate service manual. CAUTION: THE LUG NUTS MUST BE COOL ENOUGH TO TOUCH BEFORE PERFORMING THIS PROCEDURE. IF THIS PROCEDURE IS PERFORMED ON LUG NUTS THAT ARE NOT COOL ENOUGH TO TOUCH, INACCURATE TORQUE READINGS AND WHEEL CLAMP LOADS MAY RESULT. 1. Remove the center caps from each wheel. 2. Check for minimum installed wheel lug nut torque as follows: A. Set the torque wrench to 88 Nm (65 lb-ft). B. Attempt to tighten all lug nuts. ^ If any lug nut starts to rotate on the stud before the minimum torque of 88 Nm (65 lb-ft) is reached, call the Recall Hotline at 1-800-325-5621 for further instruction. ^ If all of the lug nuts on each wheel do NOT rotate before the torque wrench reaches 88 Nm (65 lb-ft), proceed with step 3. 3. Tighten all wheel lug nuts to 149 Nm (110 lb-ft) following the standard STAR pattern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1984 4. Using alcohol and a clean shop cloth, thoroughly clean the center portion of the wheels in the locations shown in Figures 2 and 3. 5. For U.S. vehicles, apply one (English) label to each wheel at the location shown. See Figure 2. 6. For Canadian vehicles, apply two (2) labels (one English and one French) to each wheel in the locations shown. See Figure 3. 7. Reinstall the center caps on each wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1985 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1986 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1987 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 1988 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener Wheel Fastener: Specifications Wheel Fastener TORQUE SPECIFICATIONS Wheel Lug Nuts: 113-153 Nm (83-112 ft. lbs.) GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric): M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener > Page 1991 Wheel Fastener: Specifications Wheel Stud GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric) ........................................................................................................................................... M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1992 Wheel Fastener: Service and Repair Removal 1. Remove the wheel hub. 2. CAUTION: Do not press on the bearing when removing or installing wheel studs. Remove the damaged wheel studs. Installation 1. CAUTION: Do not press on the bearing when removing or installing wheel studs. Install the new wheel studs. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation WARNING ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. ^ The jacking point is a raised boss located on the front suspension lower arm. The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. The rear jacking points are located on the rear axle. CAUTION: Never use the differential housing as a lifting point. Lifting WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1996 HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1997 Vehicle Lifting: Service and Repair JACKING WARNING ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. ^ The jacking point is a raised boss located on the front suspension lower arm. The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. The rear jacking points are located on the rear axle. CAUTION: Never use the differential housing as a lifting point. Lifting Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1998 WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2004 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2005 Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts 8-12 Nm (71.4-107.1 in.lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt M10 bolt: Tighten in two stages. Stage 1: Tighten to 40 Nm (30 ft.lbs.) Stage 2: Tighten an additional 90° M12 bolt: Tighten to 120 Nm (90 ft.lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2013 Camshaft Gear/Sprocket: Testing and Inspection 1. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan blade has been examined for possible cracks and separation. NOTE: Specifications show the expected minimum or maximum condition. If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. 2. Inspect the (A) timing chain/belt and the (B) sprockets. ^ Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2014 Camshaft Gear/Sprocket: Service and Repair For repair information refer to Timing Chain Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe Lift - Intake 0.2799 in Lobe Lift - Exhaust 0.2952 in Lobe Lift - Allowable Lobe Lift Loss 0.000984 in Theoretical Valve Lift @ Zero Lash - Intake 0.512 in Theoretical Valve Lift @ Zero Lash - Exhaust 0.5413 in End Play 0.00098-0.0065 in Journal to Bearing Clearance 0.00098-0.003 in Journal to Bearing Clearance - Service Limit 0.0048 in Journal Diameter (All) 1.061-1.060 in Journal Diameter (All) - Bearing Inside Diameter (All) 1.063-1.0625 in Camshaft Runout-Bearing 0.0012 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2018 Camshaft: Service and Repair Removal 1. Remove the timing chains. CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 2. Remove the camshaft roller followers. 3. On engines with bolt on sprockets, remove the camshaft sprocket. 1 Remove the bolt. 2 Remove the camshaft sprocket. 4. Remove the thirteen camshaft bearing cap bolts. 5. Remove the camshaft bearing caps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2019 6. Remove the camshaft from the cylinder head. Installation 1. Lubricate the camshaft journals. ^ Use Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Install the camshaft onto the cylinder head. 3. Lubricate the camshaft bearing caps. ^ Use Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specifications WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2020 4. Install the camshaft bearing caps. ^ Position the camshaft bearing caps. ^ Loosely install the bolts. 5. Tighten the bolts in the sequence shown. 6. Install the roller followers. 7. Install the timing chains. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2021 8. Install the camshaft bearing caps. ^ Position the camshaft bearing caps. ^ Loosely install the bolts. 9. Tighten the bolts in the sequence shown. 10. Install the roller followers. 11. Install the timing chains. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Valve Tappet - Diameter (Std) 0.66-0.629 in Valve Tappet - Clearance to Bore 0.00071-0.00272 in Valve Tappet - Service Limit 0.00063 in Valve Tappet - Hydraulic Leakdown Rate 5-25 sec Time required for the plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in tappet. Valve Tappet - Collapsed Valve Tappet Gap - Desired 0.0335-0.0177 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2025 Lifter / Lash Adjuster: Service and Repair Removal 1. Remove the camshaft roller followers. 2. Remove the valve tappets. Installation 1. Install the valve tappets. 2. Install the camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2034 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2035 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2041 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2042 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2043 Rocker Arm Assembly: Specifications Rocker Arm - Ratio 1.75 : 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2044 Rocker Arm Assembly: Service and Repair Special Tools Removal 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2045 Installation 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. 2. Remove the Valve Spring Spacer. 3. Stall the valve covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2046 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearings Clearance to Crankshaft Desired 0.001-0.0027 in Clearance to Crankshaft Allowable 0.001-0.0027 in Bearing Wall Thickness (STD) 0.096-0.0965 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bolts (In Sequence) Stage 1 30-33 ft.lb Stage 2 Rotate 90-120 Degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2055 Connecting Rod: Specifications Connecting Rod - Piston Pin Bore Diameter 0.864-0.865 in Connecting Rod - Crankshaft Bearing Bore Diameter 2.234-2.24 in Connecting Rod - Length (Center-to-Center) 5.93 in Alignment (Bore-to-Bore Max. Diff.) - Twist 0.0015 in per 0.984 in Alignment (Bore-to-Bore Max. Diff.) - Bend 0.0015 in per 0.984 in Side Clearance (Assembled to Crank) - Standard 0.0006-0.0177 in Side Clearance (Assembled to Crank) - Service Limit 0.02 in Connecting Rod Bearings Clearance to Crankshaft Desired 0.001-0.0027 in Clearance to Crankshaft Allowable 0.001-0.0027 in Bearing Wall Thickness (STD) 0.096-0.0965 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder Block Drain Plug 12-18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Pulley Bolt Stage 1 66 ft.lb Stage 2 Loosen 360 Degrees Stage 3 35-39 ft.lb Stage 4 Rotate 85-90 Degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Page 2062 Crankshaft Gear/Sprocket: Testing and Inspection 1. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan blade has been examined for possible cracks and separation. NOTE: Specifications show the expected minimum or maximum condition. If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. 2. Inspect the (A) timing chain/belt and the (B) sprockets. ^ Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Page 2063 Crankshaft Gear/Sprocket: Service and Repair For repair information refer to Timing Chain Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications Crankshaft Main Bearing: Specifications General Specifications Main Bearing Clearance to Crankshaft ......................................................................................................................... 0.027-0.065 mm (0.0011-0.0026 in) Bearing Wall Thickness .................................................................................................................................................... 1.920-1.928 mm (0.075-0.076 in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications > Page 2068 Crankshaft Main Bearing: Specifications Torque Specifications and Procedures Torque Specifications - Crankshaft Main Bearing Bolts Install the vertical main bearing cap fasteners and tighten the bolts in two stages, in the sequence shown. - Stage 1: Tighten to 40 Nm (30 ft. lbs.). - Stage 2: Tighten an additional 90 degrees. Tighten the jack screws against the cylinder block in two stages, in the sequence shown. - Stage 1: Tighten to 5 Nm (44 in. lbs.) - Stage 2: Tighten to 10 Nm (89 in. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications > Page 2069 Install the side bolts and tighten them in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > General Specifications Crankshaft: Specifications Main Bearing Journal Diameter 2.65-2.657 in Connecting Rod Journal - Diameter 2.087-2.867 in Crankshaft Free End Play 0.0051-0.012 in Crankshaft Runout to Rear Face of Block 0.002 in Crankshaft Main Bearing Journal Taper 0.0007 in Crankshaft Main Bearing Journal Runout 0.002 in Crankshaft Connecting Rod Journal Runout 0.0005 in Main Bearings Clearance to Crankshaft - Desired 0.0011 - 0.0026 in Clearance to Crankshaft - Allowable 0.0011-0.0026 in Bearing Wall Thickness (STD) 0.075-0.076 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > General Specifications > Page 2074 Crankshaft: Specifications Crankshaft Main Bearing Bolts (Cross-Mounted) Stage 1 20-24 ft.lb Stage 2 Tighten an additional 85-95 degrees Crankshaft Main Bearing Bolts (Vertical) Stage 1 27-32 ft.lb Stage 2 Tighten an additional 85-95 degrees Rear Main Oil Seal Retainer Bolts 71-106 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Removal 1. Drain the engine cooling system. 2. Disconnect the (A) block heater wire extension from the (B) block heater wiring and remove. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing fan air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. Raise and support the vehicle. 4. Disconnect the (A) block heater wiring from the (B) block heater. 5. Remove the block heater. 1. CAUTION: Do not loosen the screw more than necessary for removal. Loosen the screw. 2. Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 2078 1. NOTE: To ease installation, coat the block heater seal and the cylinder block hole with Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Tools and Equipment Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Damper Pulley Bolt Stage 1 66 ft.lb Stage 2 Loosen 360 Degrees Stage 3 35-39 ft.lb Stage 4 Rotate 85-90 Degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2085 Harmonic Balancer - Crankshaft Pulley: Service and Repair Removal 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the crankshaft pulley bolt. 4. Use the Crankshaft Damper Remover to remove the crankshaft pulley. Installation 1. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2086 Apply silicone to the woodruff key slot on the crankshaft pulley. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Use the Crankshaft Damper Replacer to install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four stages. ^ Stage 1: Tighten to 90 Nm (66.15 ft. lbs.). ^ Stage 2: Loosen the bolt. ^ Stage 3: Tighten to 47 - 53 Nm (34 - 39 ft. lbs.). ^ Stage 4: Tighten an additional 85 - 90 degrees. 4. Install the drive belt. 5. Install the engine cooling fan and the fan shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2087 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter Coded Red 1 3.550-3.551 in Coded Blue 2 3.5507-3.5515 in Coded Yellow 3 3.513-3.5521 in Piston-to-Bore Clearance 0.0005-0.001 in Pin Bore Diameter 0.866-0.8663 in Ring Groove Width Compression (Top) 0.060-0.610 in Compression (Bottom) 0.060-0.0602 in Oil Ring 0.275-0.2844 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin - Length 2.44-2.443 in Diameter 0.866-0.8661 in Pin to Piston Clearance 0.0002-0.0004 in Pin to Rod Clearance 0.0006-0.00157 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2094 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings - Ring Gap Compression (Top) (Max) 0.0394 in Compression (Bottom) (Max) 0.0394 in Oil Ring - Side Clearance (Max) 0.05 in Oil Ring - Compression (Top) 0.0016-0.0031 in Oil Ring - Compression (Bottom) 0.0012-0.00031 in Oil Ring Snug Fit Oil Ring - Service Limit 0.0006 in Ring Gap Compression (Top) 0.01-0.02 in Compression (Bottom) 0.01-0.02 in Oil Ring (Steel Rail) 0.006-0.026 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2113 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2114 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2120 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2121 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2122 Rocker Arm Assembly: Specifications Rocker Arm - Ratio 1.75 : 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2123 Rocker Arm Assembly: Service and Repair Special Tools Removal 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2124 Installation 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. 2. Remove the Valve Spring Spacer. 3. Stall the valve covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2125 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover Bolts 71-106 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side Removal 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 3. Remove the engine Air Cleaner (ACL). 4. Disconnect the crankcase ventilation hose from the valve cover. 5. Disconnect the two fuse block cable ends from the starter relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2131 6. Disconnect the two 42-pin bulkhead electrical connections and remove them from the junction block bracket. 7. Disconnect the 16-pin electrical connection and the single pin electrical connection. 8. Remove the bolts and the junction block bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2132 9. Disconnect the heater water hose. 10. Disconnect the heater water hose. 11. Disconnect the heater water hose from the heater core and remove the heater water hose. 12. Disconnect the RH fuel injector electrical connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2133 13. On 5.4L engines, disconnect the RH ignition coil electrical connections. 14. Disconnect the climate vacuum connection. 15. Raise and support the vehicle. 16. Disconnect the A/C compressor electrical connection. 17. Disconnect the Crankshaft Position (CKP) sensor electrical connection. 18. Position the wiring harness aside. 19. Lower the vehicle. 20. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: The bolts are part of the valve cover and cannot be removed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2134 Loosen the bolts and remove the valve cover. ^ Remove the valve cover gasket. Clean and inspect the mating surface. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone in two places where the engine front cover meets the cylinder head. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4C323-A6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2135 2. Position the valve cover on the cylinder head and loosely install the valve cover bolts. 3. Tighten the bolts in the sequence shown. 4. Connect the heater water hose to the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2136 5. Connect the heater water hose and position the clamp. 6. Connect the (B) heater water hose and position the (A) clamp. 7. Install the junction block bracket and the bolts. 8. Connect the 16-pin electrical connection and the single pin electrical connection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2137 9. Connect the two 42-pin bulkhead electrical connections. 10. Connect the two fuse cable leads to the starter relay. 11. Raise and support the vehicle. 12. Connect the crankshaft position sensor electrical connection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2138 13. Connect the A/C compressor electrical connection. 14. Lower the vehicle. 15. Install the Positive Crankcase Ventilation valve (PCV valve) and crankcase ventilation hose into the valve cover. 16. Install the engine air cleaner. 17. Install the accelerator control splash shield. 18. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2139 Valve Cover: Service and Repair Left Side Removal All Vehicles 1. Disconnect the battery ground cable. 2. Remove the engine air cleaner and the air cleaner outlet tube. 3. Disconnect the power steering fluid reservoir and bracket. 1 Remove the bolts. 2 Position the power steering fluid reservoir and bracket aside. 4. Remove the crankcase ventilation tube from the valve cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2140 4.6L Engine 5.4L Engine 5. Remove the Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tube. ^ Disconnect the upper and lower EGR valve-to-exhaust manifold tube fittings. ^ Disconnect the two Differential Pressure Feedback (DPFE) hoses. All Vehicles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2141 6. Disconnect the LH fuel injector electrical connections. 7. On 5.4L engines, disconnect the LH ignition coil electrical connections. 8. Disconnect the Camshaft Position (CMP) sensor. 9. Lift the engine sensor control wiring harness off of the valve cover studs. 10. NOTE: The intake manifold is removed for clarity. The bolts are part of the valve cover and should not be removed. Remove the LH valve cover. ^ Fully loosen the bolts and remove the valve cover. ^ Inspect the valve cover gasket and clean the mating surface of the cylinder head. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2142 All Vehicles 1. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-MSB392-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone in two places where the engine front cover meets the cylinder head. ^ Use Silicone Gasket and Sealer F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Position the (A) valve cover and the valve cover gasket on the (B) cylinder head, and loosely install the bolts. 3. Tighten the bolts in the sequence shown. 4. Position the engine sensor control wiring harness onto the valve cover studs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2143 5. Connect the CMP electrical connector. 6. On 5.4L engines, connect the LH ignition coil electrical connectors. 7. Connect the LH fuel injector electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2144 5.4L Engine 8. Connect the Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube upper fitting. ^ On 4.6L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand tighten. ^ Stage 2: Tighten to 35 - 45 Nm (26 - 33 ft. lbs.). ^ On 5.4L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand tighten. ^ Stage 2: Tighten to 55 - 65 Nm (41 - 47 ft. lbs.). All Vehicles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2145 9. Connect the crankcase ventilation tube to the valve cover. 10. Install the engine Air Cleaner (ACL) and air cleaner outlet tube. 11. Install the power steering fluid reservoir and bracket. 1 Position the power steering fluid reservoir and bracket. 2 Install the bolts. 12. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide Inner Diameter 0.020-0.95 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seats Width - Intake 1.3 - 1.5 mm Valve Seats Width - Exhaust 1.3 - 1.5 mm Valve Seats Angle 44.51 - 45.01 deg Valve Seats Runout (TIR) Max 0.025 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs - Compression Pressure - Intake 720-800 N at 28.02 mm Valve Springs - Compression Pressure - Exhaust 720-800 N at 28.02 mm Valve Springs - Free Length (Approximate) - Intake 2.101 in Valve Springs - Free Length (Approximate) - Exhaust 2.101 in Valve Springs - Installed Pressure - Intake 283.19-321.19 N at 42.56 mm Valve Springs - Installed Pressure - Exhaust 283.19-321.19 N at 42.56 mm Valve Springs - Installed Pressure - Service Limit 5% Pressure N at 28.8 mm Valve Springs - Installed Pressure - Out of Square Limit 2 Degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2155 Valve Spring: Service and Repair Special Tools Removal 1. Remove the camshaft roller followers. 2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. 4. Use the Valve Spring Compressor to compress the valve springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2156 5. Remove the (A) valve spring retainer keys, the (B) valve spring retainers, and the (C) valve spring. Installation 1. Position the valve spring and the valve spring retainers. 2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 3. Use the Valve Spring Compressor to compress the valve spring. Install the valve spring retainer keys. 4. Install the camshaft roller followers. 5. Install the spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2157 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Valve: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2166 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2167 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2173 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2174 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2175 Valve: Specifications Valve Stem to Guide Clearance - Intake 0.00078-0.00272 in Valve Stem to Guide Clearance - Exhaust 0.018-0.0037 in Valve Head Diameter - Intake 1.75 in Valve Head Diameter - Exhaust 1.42 in Valve Head Diameter - Gauge Diameters 1.67 and 1.26 in Valve Face Runout Limit 0.002 in Valve Face Angle 45.25-45.75 deg Valve Stem Diameter (Std) - Intake 0.275-0.2746 in Valve Stem Diameter (Std) - Exaust 0.274-0.2736 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2180 Drive Belt: Description and Operation The accessory drive consists of the: ^ drive belt ^ generator pulley ^ power steering pump pulley ^ crankshaft pulley ^ A/C clutch pulley ^ belt idler pulley ^ drive belt tensioner ^ water pump pulley The accessory drive: ^ has a single serpentine drive belt ^ has an automatic drive belt tensioner ^ does not require adjustment Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 2. Inspect the drive belt for chunking, fraying and wear. 3. Check the drive belt for correct routing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2183 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2184 Drive Belt: Component Tests and General Diagnostics Belt Tensioner NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Replace components as required. ^ Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck the drive belt tracking. ^ Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter NOTE: Tensioner is shown in free-state position against arm travel stops. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2185 Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: ^ If the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. ^ If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be replaced if no apparent damage has occurred. ^ NOTE: The drive belt tensioner arm should rotate freely without binding. ^ If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, replace the drive belt. ^ If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2186 Drive Belt: Service and Repair Removal 1. Rotate the drive belt tensioner clockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolts 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2190 Drive Belt Tensioner: Service and Repair Removal 1. Remove the drive belt. 2. Remove the bolts and the drive belt tensioner. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2195 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2196 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2197 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2198 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2199 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2200 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2201 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2202 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2203 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2204 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2205 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2206 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2207 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2208 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2209 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2210 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2211 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2212 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2213 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2214 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2215 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2216 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2217 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2218 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2219 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2220 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2221 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2222 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2223 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2224 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2225 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2226 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2227 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2228 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2229 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2230 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2231 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2232 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2233 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2234 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2235 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2236 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2237 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2238 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2239 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2240 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2241 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2242 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2243 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2244 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2245 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2246 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2247 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2248 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2249 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2251 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2252 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2253 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2254 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2255 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2256 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2257 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2258 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2259 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2260 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2261 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2262 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2263 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2264 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2265 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2266 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2267 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2268 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2269 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2270 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2271 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2272 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2273 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2274 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2275 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2276 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2277 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2278 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2279 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2280 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2281 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2282 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2283 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2284 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2285 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2286 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2287 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2288 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2289 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2290 Engine Mount: Specifications Motor Mount Cross Bolts 39-53 ft.lb Motor Mount Through Bolts 50-68 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH Engine Mount: Service and Repair LH Special Tool Removal 1. Remove the fan shroud. 2. Remove the generator. 3. Install the 3-Bar Modular Engine Support Bracket on the engine using the generator mounting holes. 4. Raise the vehicle. 5. Remove the LH motor mount bolt. 6. Loosen the RH motor mount bolt. 7. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2293 8. Install the 3-Bar Engine Support and raise the engine. 9. Raise the vehicle on the hoist. 10. Remove the bolts and remove the engine mount. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2294 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2295 Engine Mount: Service and Repair RH Special Tool Removal 1. Remove the fan shroud. 2. Remove the generator. 3. Install the 3-Bar Modular Engine Support Bracket on the engine using the generator mounting holes. 4. Raise the vehicle. 5. Remove the starter motor. 6. Remove the RH motor mount bolt. 7. Loosen the LH motor mount bolt. 8. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2296 9. Install the 3-Bar engine Support and raise the engine. 10. Raise the vehicle on the hoist. 11. Remove the RH bolts and remove the engine mount. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2297 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2298 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Drive Belt Idler Pulley Bolt 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2302 Idler Pulley: Service and Repair Removal 1. Remove the drive belt. 2. Remove bolt and belt idler pulley. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure (Hot) 138-310 kPa at 1500 rpm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Level Indicator Tube Bolt ............................................................................................................... ....................................................... 71-106 inch lbs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2310 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Removal 1. Remove LH exhaust manifold. 2. Remove the oil level indicator. 3. Remove the bolt. 4. Remove the oil level indicator tube. 5. NOTE: Lubricate the new O-ring with Ford Super Premium, SAE 5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Replace the O-ring. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2311 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug 98-143 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2319 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2320 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2321 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2322 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2325 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 NOTE: Refer to TSB# 02-1-9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2326 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil Cooler Assembly to Oil Filter Adapter Bolts 41-44 ft.lb Oil Cooler Insert 41-44 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2330 Oil Cooler: Service and Repair Removal 1. Raise and support vehicle. 2. Remove the drain plug and drain the engine oil. 3. Drain the coolant. 4. On 4x4 vehicles equipped with 5.4L engines, loosen the bolt, and remove the oil cooler. 5. NOTE: Make sure all O-ring seals are in place. On 4x2 vehicles, remove the oil bypass filter. 6. On 4x2 vehicles, remove the oil cooler insert, and remove the oil cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2331 7. Slide the hose clamps down and disconnect the coolant hoses from the oil cooler. 8. On 4x4 vehicles, remove the bolts and remove the oil cooler from the remote oil filter adapter. Installation 1. On 4x4 vehicles, position the remote oil filter adapter lines and install the nuts. 2. On 4x2 vehicles, position the coolant hoses and slide the hose clamps back. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2332 3. On 4x2 vehicles, install the oil cooler insert. 4. On 4x2 vehicles, install the oil bypass filter. 5. On 4x4 vehicles, position the oil cooler and install the bolt. 6. Install the drain plug. 7. Lower the vehicle. 8. Fill the engine with Ford Super Premium SAE 5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 9. Fill the engine coolant. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 11-12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolt 15-22 ft.lb Oil Filter Adapter Nut 30-40 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Oil Filter Adapter: Service and Repair Oil Filter Adapter Removal 1. Raise and support the vehicle. 2. Remove the lower radiator hose. 3. Remove the front drive axle assembly. 4. Remove the drain plug and drain the engine oil. 5. If the vehicle does have an oil cooler, remove the oil cooler. 6. Disconnect the oil pressure sender electrical connector. 7. On vehicles equipped with a remote oil filter adapter, remove the nuts and position the remote oil filter adapter aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2341 8. Remove the four bolts and the oil filter adapter. Installation 1. If equipped with a remote oil filter adapter, position the oil filter adapter and install the four bolts. ^ Install a new oil filter adapter gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2342 2. Position the remote oil filter adapter and install the nuts. 3. On vehicles not equipped with a remote oil filter adapter, position the oil filter adapter and install the four bolts. ^ Install a new oil filter adapter gasket. ^ Position the oil filter adapter and install the four bolts. 4. Connect the oil pressure sender electrical connector. 5. If the vehicle is equipped with an oil cooler, install the oil cooler. 6. Install the drain plug. 7. Install the front drive axle assembly. 8. Install the lower radiator hose. 9. Lower the vehicle. 10. Fill the engine with Ford Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2343 Oil Filter Adapter: Service and Repair Remote Adapter Removal 1. Raise and support the vehicle. 2. Remove the drain plug and drain the engine oil. 3. If equipped with an oil cooler, remove the two nuts and disconnect the remote oil filter adapter from the oil cooler. 4. If the vehicle is not equipped with an oil cooler, disconnect the oil pressure sender electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2344 5. Remove the two nuts and disconnect the remote oil filter adapter. 6. Remove the oil filter. 7. Remove the bolts, and remove the remote oil filter adapter. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2345 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2346 1. Follow the removal procedure in reverse order. ^ Fill the engine with Ford Super Premium SAE 5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2347 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications > Oil Cooler Line Oil Line: Specifications Remote Oil Cooler Line to Cylinder Block 71-106 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications > Oil Cooler Line > Page 2352 Oil Line: Specifications Oil Line Oil Line Connector Adapter Assembly Bolt ...................................................................................................................................................... 15-22 ft. lbs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts Stage 1 18 in.lb Stage 2 15 ft.lb Stage 3 Tighten an additional 60 degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2356 Oil Pan: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the front drive axle assembly. 3. Remove the drain plug and drain the engine oil. 4. Remove the bolts. 5. NOTE: Be careful when removing the oil pan gasket. The oil pan gasket is reusable if it is not damaged. Remove the oil pan and oil pan gasket. ^ Inspect oil pan gasket for damage. ^ Replace if necessary. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the mating surfaces. 2. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2357 Apply the silicone at the rear oil seal retainer to cylinder block sealing surface. ^ Use Ford Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 3. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone at the engine front cover to the cylinder block sealing surface. ^ Use Ford Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. 5. NOTE: Make sure to tighten the bolts in three stages. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2358 Tighten the bolts in the sequence shown. ^ Stage 1: Tighten to 2 Nm (18 inch lbs.). ^ Stage 2: Tighten to 20 Nm (15 ft. lbs.). ^ Stage 3: Tighten an additional 60 degrees. 6. Install the front drive axle assembly. 7. Lower the vehicle. 8. Fill the engine with oil. ^ Use Ford Super Premium SAE 5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch 9-11 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2365 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil Pump Screen Cover and Tube Bolts 71-106 in.lb Oil Pump Screen Cover and Tube Spacer 15-22 in.lb Oil Pump Screen Cover and Tube Spacer Bolt 15-22 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Page 2369 Oil Pick Up/Strainer: Service and Repair Removal 1. Remove the oil pan. 2. Remove the three (A) bolts and the (B) oil pump screen cover and tube. Installation 1. NOTE: Lubricate the new O-ring with Ford Super Premium SAE 5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Clean and inspect the mating surfaces and replace the O-ring. 2. Install the oil pump screen cover and tube and install the bolts. 3. Install the oil pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure (Hot) 138-310 kPa at 1500 rpm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Lower Intake Manifold to Upper Intake Manifold Bolts Stage 1 18 in.lb Stage 2 71-106 in.lb Upper Intake Manifold to Cylinder Head Bolts Stage 1 18 in.lb Stage 2 71-106 in.lb Throttle Body Fasteners 80 in.lb Intake Manifold Tuning Valve Screws 71-106 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2377 Intake Manifold: Service and Repair Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. All Vehicles 1. Disconnect the battery ground cable. 2. Perform pre-service procedures. 3. Drain the cooling system. 4. Compress and slide the hose clamp and disconnect the upper radiator hose. 5. Remove the engine Air Cleaner (ACL) and air cleaner outlet tube. 6. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 7. Disconnect the accelerator cable from the accelerator cable bracket. 1 Remove the bolt. 2 Slide the accelerator cable up to remove it from the accelerator cable bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2378 8. Disconnect the accelerator cable from the throttle body cam. 1 Roll the throttle body cam forward. 2 Slide the accelerator cable end from the throttle body cam. 9. Remove the throttle return spring. 10. If equipped, disconnect the speed control actuator cable from the throttle body. 1 Remove the speed control actuator cable to the bolt. 2 Disconnect the (A) speed control actuator cable from the (B) throttle body cam and position aside. 11. Disconnect the climate control vacuum hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2379 12. Remove the bolt and the brake booster vacuum hose and bracket. 13. Disconnect the connector from the throttle position (TP) sensor. 4.6L Engine 14. Disconnect the following throttle body hose connections: ^ vapor management hose (1) ^ Positive Crankcase Ventilation valve (PCV valve) (2) ^ power brake booster (3) All Vehicles 15. On 4.6L engines, remove the (A) brake booster vacuum hose bracket nut from the (B) brake booster vacuum hose bracket. 16. Disconnect the fuel lines. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2380 17. Disconnect the PCV and PCV coolant hoses. 18. Disconnect the following electrical connectors: ^ Differential Pressure Feedback (DPFE) transducer Engine Vacuum Regulator (EVR) sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2381 19. Remove the Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube. ^ Disconnect the upper and lower EGR valve to exhaust manifold tube fittings. ^ Disconnect the two DPFE hoses. 4.6L Engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2382 5.4L Engine 20. Disconnect the following vacuum connections: 1 EGR vacuum hose 2 vacuum supply port 3 EVR vacuum hose 4 fuel pressure regulator vacuum hose All Vehicles 21. Disconnect the RH fuel injector electrical connectors. 22. Disconnect the LH fuel injector electrical connectors. 23. On 5.4L engines, disconnect and remove the eight ignition coils. 24. Remove the drive belt. 25. Remove the Generator (GEN). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2383 26. Remove the bolts and the throttle body. 27. Disconnect the hose clamp and remove the heater water hose. 28. Remove the studs. 29. Remove the water thermostat. 30. Remove the nine bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2384 31. Remove the upper intake manifold. 1 Lift the intake manifold. 2 Disconnect the Intake Manifold Tuning Valve (IMTV) connector. (4.6L engine only.) 3 Remove and discard the upper intake manifold gaskets. 32. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2385 33. Separate the upper intake manifold from the lower intake manifold and discard the lower intake manifold gasket. 34. Remove the (A) pushpin from the (B) intake manifold insulator and remove from the (C) lower intake manifold. 35. Remove the (A) bolts from the (B) intake manifold tuning valve and remove the intake manifold tuning valve. (4.6L engine only.) Installation All Vehicles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2386 1. Position the intake manifold tuning valve and install the bolts. (4.6L engine only.) 2. Install the intake manifold insulator on the lower intake manifold and install the pushpin. 3. Position the lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the eight bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2387 4. Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 inch lbs.) Stage 2: 8 - 12 Nm (71 - 106 inch lbs.) 5. Install the studs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2388 6. Install the upper intake manifold. ^ Position the upper intake manifold gaskets. ^ Position the upper intake manifold. ^ Loosely install the nine bolts. 7. Connect the intake manifold tuning valve connector. (4.6L engine only.) 8. Install the water thermostat. 9. Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 inch lbs.) Stage 2: 20 - 30 Nm (15 - 22 ft. lbs.) 10. Position the throttle body onto the upper intake manifold and install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2389 11. Install the heater water hose and position the clamp. 12. Install the generator. 13. Install the drive belt. 14. On 5.4L engines, install the eight ignition coils. 15. Connect the LH fuel injector electrical connectors. 16. Connect the RH fuel injector electrical connectors. 17. NOTE: For 4.6L engine-equipped vehicles, perform the following step. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2390 4.6L Engine 5.4L Engine Connect the following vacuum connections: 1 Exhaust Gas Recirculation (EGR) vacuum hose 2 vacuum supply port 3 Engine Vacuum Regulator (EVR) vacuum hose 4 fuel pressure regulator vacuum hose Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2391 18. Connect the EGR valve to exhaust manifold tube upper sting. ^ On 4.6L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand-tighten. ^ Stage 2: Tighten to 35 - 45 Nm (26 - 33 ft. lbs.). ^ On 5.4L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand-tighten. ^ Stage 2: Tighten to 55 - 65 Nm (41 - 47 ft. lbs.). All Vehicles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2392 19. Connect the following electrical connectors: ^ Differential Pressure Feedback (DPFE) transducer ^ Engine Vacuum Regulator (EVR) sensor 20. Connect the Positive Crankcase Ventilation (PCV) and PCV coolant hoses. 21. On 4.6L engines, position the brake booster vacuum hose bracket and install the nut. 22. Connect the following electrical connectors: ^ DPFE transducer ^ engine vacuum regulator sensor 23. Connect the fuel lines. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2393 24. Connect the climate control vacuum hose. 25. Install the throttle return spring. 26. Connect the accelerator cable to throttle body cam. 1 Rotate the throttle body cam forward. 2 Slide the accelerator cable into the throttle body cam. 27. Connect the accelerator cable to accelerator cable bracket. 1 Slide the accelerator cable into the accelerator cable bracket. 2 Install the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2394 28. Install the accelerator control splash shield. 29. Install the air cleaner outlet tube and the engine air cleaner. 30. Install the upper radiator hose and reposition the clamp. 31. Fill the cooling system. 32. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation Crankshaft Main Bearing Seal: Service and Repair Removal and Installation Special Tools Removal 1. Remove the transmission. 2. Remove the flywheel. 3. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 4. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation > Page 2404 tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Lubricate the inner lip of the rear crankshaft seal with Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. 2. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 3. Install the flywheel. 4. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation > Page 2405 Crankshaft Main Bearing Seal: Service and Repair With Retainer Plate Special Tools Removal 1. Remove the transmission. 2. Remove the oil pan. 3. Remove the flywheel. 4. Use the (A) Rear Crank Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 5. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation > Page 2406 6. If the oil dye leak test reveals a leak behind the retainer, remove the six bolts and the crankcase rear oil seal retainer. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surface. 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. The silicone must be applied on the groove along the retainer plate. Apply a 4mm (0.16 inch) bead of silicone around the rear oil seal retainer sealing surface. ^ Use Silicone Gasket and sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. 3. Install the rear oil seal retainer and loosely install the six bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal and Installation > Page 2407 4. Tighten the bolts in the sequence shown. 5. NOTE: Lubricate the inner lip of the rear crankshaft seal with Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. 6. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 7. Install the flywheel. 8. Install the oil pan. 9. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: Customer Interest Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2416 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2417 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2418 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak Cylinder Head Gasket: Customer Interest Head Gasket - Right Hand Side Oil Leak Article No 01-12-2 06/25/01 ENGINE - OIL LEAK FROM RIGHT SIDE HEAD GASKET AREA - VEHICLES EQUIPPED WITH 4.6L/5.4L WINDSOR ENGINE ONLY - SERVICE TIPS FORD: 1999 E-150, E-250, EXPEDITION, F-150, F-250 LD, SUPER DUTY F SERIES LINCOLN: 1999 NAVIGATOR ISSUE On some vehicles there may be an oil leak from the right hand head gasket at the rear of the block/head joint. This may be caused by metal chip debris lodged between the head gasket and the block. ACTION Verify oil leak. Inspect for metal chips, impressions or dimples in the metal at the right bank cylinder head and block deck areas behind cylinder 4 at the area of the cast triangular recess in the cylinder head deck. Also inspect around the oil hole breakout in the block deck. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the origin of the oil seep by adding fluorescent dye to the oil. Run the engine for 10 minutes and shut down. Start the engine after a 2 hour soak and run the engine for 10 minutes. Inspect the rear of the right hand cylinder head to block joint with an ultra-violet light ("black light") for oil stains and drips. 2. If the oil seep has been established as coming from the cylinder head to block joint, remove the cylinder head and head gasket per the Workshop Manual. 3. Clean both the block and cylinder head decks of residual gasket coating with Motorcraft Metal Surface Cleaner F4AZ-19A536-RA or equivalent. NOTE DO NOT USE A METAL TOOL OF ANY KIND ON THE GASKET SEALING SURFACE. RESULTING SCRATCHES WILL PROVIDE A LEAK PATH. USE PLASTIC OR WOOD SCRAPERS ONLY. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak > Page 2423 4. Inspect for the dimples and impressions. (Figures 1 and 2). 5. If no permanent damage to the block and cylinder head decks is found, replace the cylinder head gasket using current service replacement parts. 6. It damage is found, refer to the CYLINDER HEAD DECKS or CYLINDER BLOCK DECKS Instructions that follow. CYLINDER HEAD DECKS If such damage is spotted, check for flatness with a straight edge over the dimple or impression. If the dimple or impression on the head measures over .025 mm (.001 ") deep, the cylinder head, gasket and bolts should be replaced with new. Refer to the parts listing table that follows. CYLINDER BLOCK DECKS Check for flatness with a straight edge over the dimple or impression. If the dimple or impression measures over .025 mm (.001") deep, the engine should be replaced. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 40100, 499000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: All Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2430 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2431 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2436 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2437 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2438 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2443 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2444 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak Cylinder Head Gasket: All Technical Service Bulletins Head Gasket - Right Hand Side Oil Leak Article No 01-12-2 06/25/01 ENGINE - OIL LEAK FROM RIGHT SIDE HEAD GASKET AREA - VEHICLES EQUIPPED WITH 4.6L/5.4L WINDSOR ENGINE ONLY - SERVICE TIPS FORD: 1999 E-150, E-250, EXPEDITION, F-150, F-250 LD, SUPER DUTY F SERIES LINCOLN: 1999 NAVIGATOR ISSUE On some vehicles there may be an oil leak from the right hand head gasket at the rear of the block/head joint. This may be caused by metal chip debris lodged between the head gasket and the block. ACTION Verify oil leak. Inspect for metal chips, impressions or dimples in the metal at the right bank cylinder head and block deck areas behind cylinder 4 at the area of the cast triangular recess in the cylinder head deck. Also inspect around the oil hole breakout in the block deck. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the origin of the oil seep by adding fluorescent dye to the oil. Run the engine for 10 minutes and shut down. Start the engine after a 2 hour soak and run the engine for 10 minutes. Inspect the rear of the right hand cylinder head to block joint with an ultra-violet light ("black light") for oil stains and drips. 2. If the oil seep has been established as coming from the cylinder head to block joint, remove the cylinder head and head gasket per the Workshop Manual. 3. Clean both the block and cylinder head decks of residual gasket coating with Motorcraft Metal Surface Cleaner F4AZ-19A536-RA or equivalent. NOTE DO NOT USE A METAL TOOL OF ANY KIND ON THE GASKET SEALING SURFACE. RESULTING SCRATCHES WILL PROVIDE A LEAK PATH. USE PLASTIC OR WOOD SCRAPERS ONLY. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak > Page 2449 4. Inspect for the dimples and impressions. (Figures 1 and 2). 5. If no permanent damage to the block and cylinder head decks is found, replace the cylinder head gasket using current service replacement parts. 6. It damage is found, refer to the CYLINDER HEAD DECKS or CYLINDER BLOCK DECKS Instructions that follow. CYLINDER HEAD DECKS If such damage is spotted, check for flatness with a straight edge over the dimple or impression. If the dimple or impression on the head measures over .025 mm (.001 ") deep, the cylinder head, gasket and bolts should be replaced with new. Refer to the parts listing table that follows. CYLINDER BLOCK DECKS Check for flatness with a straight edge over the dimple or impression. If the dimple or impression measures over .025 mm (.001") deep, the engine should be replaced. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 40100, 499000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: All Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2456 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2457 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2462 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2463 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Special Tools Removal 1. Remove the crankshaft pulley. 2. Use the (A) Front Cover Seal Remover to remove the (B) front cover seal. Installation 1. Lubricate the (A) and the (B) front oil seal inner lip. ^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2467 2. Use the (A) Crankshaft Seal Replacer/Cover Aligner to install the (B) into the (C). 3. Install the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2468 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Special Tools Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. NOTE: The valve stem seal must be bottomed on the valve seat. Make sure that the garter spring is present in the valve stem seal. Use the (A) Valve Stem Seal Replacer to install the (B) valve stem seals. 2. Install the valve springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2472 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch 9-11 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2477 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt M10 bolt: Tighten in two stages. Stage 1: Tighten to 40 Nm (30 ft.lbs.) Stage 2: Tighten an additional 90° M12 bolt: Tighten to 120 Nm (90 ft.lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2482 Camshaft Gear/Sprocket: Testing and Inspection 1. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan blade has been examined for possible cracks and separation. NOTE: Specifications show the expected minimum or maximum condition. If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. 2. Inspect the (A) timing chain/belt and the (B) sprockets. ^ Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2483 Camshaft Gear/Sprocket: Service and Repair For repair information refer to Timing Chain Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Pulley Bolt Stage 1 66 ft.lb Stage 2 Loosen 360 Degrees Stage 3 35-39 ft.lb Stage 4 Rotate 85-90 Degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Page 2487 Crankshaft Gear/Sprocket: Testing and Inspection 1. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan blade has been examined for possible cracks and separation. NOTE: Specifications show the expected minimum or maximum condition. If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. 2. Inspect the (A) timing chain/belt and the (B) sprockets. ^ Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Page 2488 Crankshaft Gear/Sprocket: Service and Repair For repair information refer to Timing Chain Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Tools and Equipment Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Guide Bolts 71-106 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications > Page 2495 Timing Chain Guide: Service and Repair For repair information refer to Timing Chain Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Hydraulic Tensioner Bolts 15-22 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2499 Timing Chain Tensioner: Service and Repair For repair information refer to Timing Chain Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolts (1-5) 15-22 ft.lb Engine Front Cover Bolts (6-15) 30-40 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2503 Timing Cover: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove both valve covers. 3. Remove the radiator. 4. Remove the water pump. 5. Disconnect the following electrical connections: ^ LH ignition coil connector (A). ^ Camshaft Position (CMP) sensor electrical connector (B). ^ Radio capacitor electrical connector (C). 6. Disconnect the following electrical connections: ^ RH ignition coil electrical connector (A) ^ radio capacitor electrical connector (B) 7. Remove the ignition coils and the ignition coil mounting brackets. 1 Remove the bolts. 2 Remove the RH ignition coil and the ignition coil mounting bracket. 3 Remove the bolt. 4 Remove the nuts. 5 Remove the LH ignition coil and ignition coil mounting bracket. 8. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2504 9. Remove the bolts and position the power steering pump aside. 10. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 11. Remove the oil pan drain plug and drain the engine oil. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2505 12. Remove the bolts. 13. Lower the vehicle. 14. Remove the crankshaft front seal. 15. Remove the (A) bolt and the (B) belt idler pulley. 16. Remove the bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2506 17. Remove the engine front cover from the front cover to cylinder block dowel. Installation 1. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or four minutes, which ever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone along the cylinder head to block surface and the oil pan to cylinder block surface. ^ Use Silicone Gasket and sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Install the engine front cover on the front cover to cylinder block dowel and loosely install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2507 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2508 3. Tighten the front cover bolts and stud bolts in sequence in two stages. Stage 1: Tighten fasteners 1 - 7 to 20 - 30 Nm (15 - 22 ft. lbs.). Stage 2: Tighten fasteners 6 - 15 to 40 - 55 Nm (29 - 40 ft. lbs.). 4. Position the (A) belt idler pulley and install the (B) bolt. 5. Install a new crankshaft front oil seal. 6. Raise and support the vehicle. 7. Loosely install the front bolts. 8. NOTE: Make sure to tighten the bolts in two stages. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2509 Tighten the bolts in the sequence shown in two stages. ^ Stage 1: Tighten to 20 Nm (15 ft. lbs.). ^ Stage 2: Tighten an additional 60 degrees. 9. Connect the Crankshaft Position (CKP) sensor electrical connector. 10. NOTE: The front lower hole in the power steering pump is not used. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2510 Position the power steering pump and install the bolts. 11. Install the oil pan drain plug. 12. Lower the vehicle. 13. Install the ignition coils and brackets. 1 Position the LH ignition coil and the ignition coil mounting bracket. 2 Install the LH nuts. 3 Install the LH bolt. 4 Position the RH ignition coil and ignition coil mounting bracket. 5 Install the RH bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2511 14. Connect the following electrical connections: ^ RH ignition coil electrical connector (A) ^ radio capacitor electrical connector (B) 15. Connect the following electrical connections: ^ LH ignition coil connector (A) ^ Camshaft Position (CMP) electrical connector (B) ^ radio capacitor electrical connector (C) 16. Install the valve covers. 17. Fill the engine with oil. ^ Use Ford Super Premium SAE 5W-30 Motor Oil XO-5W-30 DPS or equivalent meeting Ford specification WSS-M2C153-G. 18. Install the water pump. 19. Install the radiator. 20. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 2517 Fuel Pressure Test Port: Description and Operation The Fuel Pressure Relief valve: ^ is used to inspect and relieve fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 2518 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2526 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) Outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2537 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2538 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Description and Operation Ignition Cable: Description and Operation The spark plug wires carry high voltage pulses from the ignition coil to the spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Description and Operation > Page 2546 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. To install. reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2551 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2552 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2553 Spark Plug: Description and Operation The spark plug. ^ change the high voltage pulse from the ignition coil into a spark which ignites the fuel and air mixture. ^ are different for the LH and RH side of the engine. ^ originally equipped on the vehicle have a Platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2554 Spark Plug: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Remove the spark plugs. NOTE: Remove any foreign materials from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2555 5. Inspect for carbon fouling ^ Look for black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with a incorrect heat range, dirty air cleaner, too rich fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating identified by a white or light gray-brown spots and white bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with a incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2556 9. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2560 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2561 Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water Pump Pulley Ratio .................................................................................................................... .............................................................................. 1.3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2574 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications 1 row radiator and standard heater 20.5 L 2 row radiator and standard heater 21.8 L 1 row radiator and aux. rear heater 21.7 L 2 row radiator and aux. rear heater 23.5 L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2577 Coolant: Fluid Type Specifications Coolant Type ....................................................................................................................................... ................................ Ford Premium Engine Coolant Ford Specification................................................................................................................................. .........................................................ESE-M97B44-A Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe Engine Coolant (orange in color). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2578 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder Block Drain Plug 12-18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Degas Bottle Bolts ............................................................................................................................... .................................................... 9 Nm (80 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2585 Coolant Reservoir: Service and Repair Removal 1. Partially drain the cooling system. 2. Remove the hose from the radiator. 1 Release the hose clamp and slide away from the hose end. 2 Slide the hose off the radiator fitting. 3. Remove the lower radiator hose from the degas bottle. 4. Remove the degas bottle. 1 Remove the bolts. 2 Remove the degas bottle. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications Fan Blade to Fan Clutch Bolts ............................................................................................................. ..................................................... 17 Nm (13 ft. lbs.) Fan Blade and Fan Clutch to Water Pump Pulley ..................................................................................................................................... 55 Nm (41 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2590 Fan Blade: Service and Repair Special Service Tool(s) (Part 1) Removal WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions may result in personal injury. NOTE: The fan clutch and shroud must be removed as an assembly. 1. Remove the air cleaner. 2. Drain the engine cooling system. 3. Remove the front air deflector. 1 Remove the screws. 2 Remove the front air deflector. 4. Remove the upper radiator hose from the radiator. 5. Remove the degas bottle hose from the radiator. 1 Release the (A) hose clamp and slide it away from the end of the (B) hose. 2 Slide the (A) coolant recovery reservoir hose off the (B) radiator fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2591 6. Remove the fan blade and fan clutch. 1 Use Fan Clutch Holding Tool to hold the water pump pulley steady. 2 Use Fan Clutch Wrench to remove the fan blade and the fan clutch. 7. Remove the fan shroud. 1 Remove the screws. 2 Lift and remove the fan shroud and fan blade out of the vehicle together. 8. Remove the fan and shroud out of the vehicle together. 9. Separate the fan clutch from the fan blade. 1 Remove the bolts. 2 Separate the (A) fan blade from the (B) fan clutch. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2592 1. Assemble the fan clutch to the fan blade. 1 Position the (A) fan clutch on the (B) fan blade. 2 Install the bolts. 2. Position the fan shroud and the fan blade. 3. Install the fan shroud. 1 Lower the fan shroud onto the radiator clips. 2 Install the screws. 4. Install the fan blade and the fan clutch. 1 Position the fan blade assembly and the fan clutch on the water pump pulley. 2 Use Fan Clutch Holding Tool to hold the water pump pulley steady. 3 Use Fail Clutch Wrench to install the fan blade and fan clutch. 5. Connect the degas bottle hose to the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2593 1 Push the (A) degas bottle hose onto the (B) radiator fitting. 2 Position and tighten the hose clamp. 6. Connect the upper radiator hose to the radiator. 7. Install the front air deflector. 1 Position the front air deflector. 2 Install the screws. 8. Fill the engine cooling system. 9. Install the Air Cleaner (ACL). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 2594 Special Service Tool(s) (Part 1) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan Blade and Fan Clutch to Water Pump Pulley 41 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 2598 Fan Clutch: Service and Repair Special Service Tool(s) (Part 1) Removal WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions may result in personal injury. NOTE: The fan clutch and shroud must be removed as an assembly. 1. Remove the air cleaner. 2. Drain the engine cooling system. 3. Remove the front air deflector. 1 Remove the screws. 2 Remove the front air deflector. 4. Remove the upper radiator hose from the radiator. 5. Remove the degas bottle hose from the radiator. 1 Release the (A) hose clamp and slide it away from the end of the (B) hose. 2 Slide the (A) coolant recovery reservoir hose off the (B) radiator fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 2599 6. Remove the fan blade and fan clutch. 1 Use Fan Clutch Holding Tool to hold the water pump pulley steady. 2 Use Fan Clutch Wrench to remove the fan blade and the fan clutch. 7. Remove the fan shroud. 1 Remove the screws. 2 Lift and remove the fan shroud and fan blade out of the vehicle together. 8. Remove the fan and shroud out of the vehicle together. 9. Separate the fan clutch from the fan blade. 1 Remove the bolts. 2 Separate the (A) fan blade from the (B) fan clutch. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 2600 1. Assemble the fan clutch to the fan blade. 1 Position the (A) fan clutch on the (B) fan blade. 2 Install the bolts. 2. Position the fan shroud and the fan blade. 3. Install the fan shroud. 1 Lower the fan shroud onto the radiator clips. 2 Install the screws. 4. Install the fan blade and the fan clutch. 1 Position the fan blade assembly and the fan clutch on the water pump pulley. 2 Use Fan Clutch Holding Tool to hold the water pump pulley steady. 3 Use Fail Clutch Wrench to install the fan blade and fan clutch. 5. Connect the degas bottle hose to the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 2601 1 Push the (A) degas bottle hose onto the (B) radiator fitting. 2 Position and tighten the hose clamp. 6. Connect the upper radiator hose to the radiator. 7. Install the front air deflector. 1 Position the front air deflector. 2 Install the screws. 8. Fill the engine cooling system. 9. Install the Air Cleaner (ACL). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment > Special Tools Special Service Tool(s) (Part 1) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment > Special Tools > Page 2604 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool - Ast (8005) Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2609 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2610 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water Temperature Sensor 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 2614 Temperature Sensor (Gauge): Service and Repair Removal 1. Partially drain the engine cooling system. 2. On 4.6L engines, disconnect the connector and remove the water temperature indicator sender unit. 3. On 5.4L engines, disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. ^ Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud Bolts 80 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2626 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2627 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2633 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2634 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2635 Heater Core: Specifications Heater Core Bracket Screws 1.5-2.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear heater core which operates in the same manner as the front heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary > Page 2638 Heater Core: Description and Operation Heating and Defrosting Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2639 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: ^ the heater core may have an air pocket ^ the heater core may be plugged. ^ the thermostat may not be working correctly. Heater Core-Pressure Test Use the radiator/heater core pressure tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2640 Heater Core-Bench Test Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heating and Defrosting Heater Core: Service and Repair Heating and Defrosting REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Disconnect the heater core hose couplings. 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter 6. Disconnect the vacuum line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heating and Defrosting > Page 2643 7. Remove the heater core bracket. 1 Remove the two screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heating and Defrosting > Page 2644 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heating and Defrosting > Page 2645 Heater Core: Service and Repair Auxillary Heating System Removal 1. Remove the air conditioning and heater assembly. Refer to: " Heater Core Case : Service and Repair" See: Heating and Air Conditioning/Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1. Remove the ten bolts. 2. Remove the evaporator/heater core access cover. 3. Remove the heater core. Installation 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2654 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2655 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2661 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2662 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2663 Heater Hose: Specifications Hose Clamp 2-3 Nm Front Auxiliary Heater Line Brackets 8 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2664 Heater Hose: Description and Operation Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2665 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line The auxiliary lines are two-piece tubes that are secured to the underbody of the vehicle. New auxiliary line kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line Heater Hose: Service and Repair Front Auxiliary Heater Outlet and Inlet Line REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Loosen the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Move the front fender splash shield to access the lines. 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2668 8. Disconnect the heater outlet line from the outlet hose coupling. 9. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. 10. Cut the heater outlet line where it crosses under the frame. 11. Cut the heater outlet line near the front wheel well opening. 12. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2669 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2670 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line NOTE: The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater outlet line. ^ Install the end with the blue tape over the flame. 2. Connect the heater outlet line peanut fitting. 1 Connect the fitting. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Install the end with the red tape over the frame. ^ Install the end with the yellow tape between the frame and the body vertical flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2671 NOTE: View shown with fender skirt removed for clarity. 4. Connect the heater water outlet line to the heater water outlet line. 1 Connect the fitting. 2 Loosely install the nut. 5. Install the heater water outlet line to the heater water outlet line. ^ Install the line through the wheel opening. NOTE: Fender skirt removed for clarity. 6. Connect the heater water outlet line to the heater water outlet line. 1 Connect the fitting. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2672 7. Tighten the three peanut fittings. 8. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION Verify that clearance exists between the frame and the lines to prevent component damage. - Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 9. Connect the heater water outlet line to the engine heater outlet hose coupling. 10. Install the bolts, the pin-type retainers and the front fender splash shield. 11. Install the wheel and tire assembly. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2673 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retailer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2674 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESR-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2675 Heater Hose: Service and Repair Rear Auxiliary Heater Inlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2676 9. Remove the our me bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 12. Cut the heater inlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2677 13. Cut the heater inlet line near the rear crossmember. 14. Cut the heater inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2678 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2679 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the green tape over the rear axle between the frame crossmember and the body. 2. Connect the heater inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape between the frame crossmember and the floor pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2680 4. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the red tape between the frame and the body. 6. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. ^ Install the end with the green tape through the floor opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2681 8. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2682 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2683 Heater Hose: Service and Repair Rear Auxiliary Heater Outlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2684 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 12. Cut the heater outlet line near the grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2685 13. Cut the heater outlet line near the rear cross member. 14. Cut the heater outlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2686 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2687 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape over the axle between the frame and the body. 2. Connect the heater outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the red tape between the frame and the floor pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2688 4. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. 1 Remove RH rear wheel and tire. 2 Install the end with blue tape between the frame and the body. 6. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. ^ Install the end with the hose through the floor opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2689 8. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nuts. 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2690 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater outlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2691 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Disconnect the heater core hose couplings. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 2692 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Page 2693 Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 2706 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 2707 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 2708 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 2714 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 2715 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 2716 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2717 Radiator: Specifications Radiator Support Bracket 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2718 Radiator: Service and Repair Removal 1. Drain the engine cooling system. 2. Remove the fan blade. 3. Disconnect the transmission fluid cooler fittings. 1 Disconnect the upper transmission fluid cooler fitting. 2 Disconnect the lower transmission fluid cooler fitting. 4. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect the lower radiator hose. 5. Remove the radiator. 1 Remove the bolts. 2 Remove the upper radiator support brackets and the jack handle and wheel nut wrench retainers. 3 Lift the radiator off the radiator mounting insulators. 4 Remove the radiator mounting insulators Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2719 1. Install the radiator. 1 Install the radiator mounting insulators. 2 Position the radiator on the radiator mounting insulators. 3 Position the brackets and the jack handle and wheel nut wrench retainers. 4 Install the bolts. 2. Connect the lower radiator hose and upper radiator hose. 1 Push the hose onto quick connect fitting. 2 Bend the locking tab into retaining slot. 3. Connect the transmission fluid cooler lines. 1 Connect the lower transmission fluid cooler line. 2 Connect the upper transmission fluid cooler line. 4. Install the fan blade. 5. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Relief Cap Opening Pressure 16 psi Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) Removal 1. Drain the engine cooling system. 2. Remove inlet side of Air Cleaner (ACL). 3. Disconnect the lower radiator hose from the oil filter adapter. 4. Disconnect the lower radiator hose from the degas bottle. 5. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. Raise and support the vehicle. 6. If equipped with engine oil cooler, disconnect the lower radiator hose connections from the oil cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 2727 7. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect and remove the lower radiator hose. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. The lower radiator hose does not require rotation for installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 2728 Radiator Hose: Service and Repair Radiator Hoses (Upper) Removal 1. Partially drain the engine cooling system. 2. Remove the upper radiator hose. 1 Release the hose clamps and slide away from the hose ends. 2 Remove the upper radiator hose. Installation 1. NOTE: Make sure that the upper radiator hose is seated in the upper hose support bracket. Install the upper radiator hose. 1 Position the upper radiator hose. 2 Compress and position the hose clamps. 2. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2734 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2735 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water Temperature Sensor 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 2739 Temperature Sensor (Gauge): Service and Repair Removal 1. Partially drain the engine cooling system. 2. On 4.6L engines, disconnect the connector and remove the water temperature indicator sender unit. 3. On 5.4L engines, disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. ^ Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Start to Open Temperature 188-195 F Full Open Temperature 212 F Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2746 Thermostat: Service and Repair Removal 1. Partially drain the engine cooling system. 2. Remove the upper radiator hose. 3. Remove the water hose connection. 1 Remove the bolts. 2 Remove the water hose connection. 4. Remove the (A) water thermostat and the (B) O-ring. Discard the (B) O-ring. Installation 1. Use a new (A) O-ring and position the (B) water thermostat in the (C) upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2747 2. Install the water hose connection. 1 Position the (A) water hose connection on the (B) upper intake manifold. 2 Install the bolts. 3. NOTE: Make sure that the upper radiator hose is seated in the upper hose bracket. Connect the upper radiator hose. 1 Position the upper radiator hose. 2 Compress and position the constant tension clamp. 4. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolts 15-22 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water Pump Pulley Ratio .................................................................................................................... .............................................................................. 1.3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2760 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2761 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2762 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2763 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2764 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2765 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2766 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2767 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2768 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2769 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2770 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2771 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2772 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2773 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2774 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2775 Catalytic Converter: Specifications Three Way Catalytic Converter to Exhaust Manifold Nuts 25-33 ft.lb Exhaust Converter Frame Bracket to Catalytic Converter Pip Nuts 25-33 ft.lb LH to RH Catalytic Converter Pipe Clamp Nuts 35-46 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2776 Catalytic Converter: Service and Repair Removal 1. Remove the muffler and tail pipe assembly. 2. Disconnect the two Heated Oxygen Sensors (H02S) and the two Catalyst Monitor Sensor (CMSs) connectors. 3. Remove the nuts. 4. Remove the transfer case skid plate. 1 Remove the four bolts. 2 Remove the transfer case skid plate. 5. Remove the bolt. 6. Use High-Lift Jack to support the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2777 7. Remove the transmission support crossmember to transmission support insulator nuts. 8. Remove the transmission support crossmember. 1 Remove the three LH bolts and the three RH bolts. 2 Remove the transmission support crossmember. 9. On 4.6L equipped vehicles, remove the exhaust hanger nut. 10. On 5.4L equipped vehicles, remove the exhaust hanger nut. 11. Remove the two three-way catalytic converters. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2778 12. On 4.6L equipped vehicles, if only one Three-Way Catalytic Converter (TWC) is being replaced, remove clamp. 13. NOTE: It may be necessary to heat the LH/RH three-way catalytic converter joint to ease removal. Separate the LH and RH three-way catalytic converters. 14. On 5.4L equipped vehicles, if only one three-way catalytic converter is being replaced, remove the clamp. 15. NOTE: It may be necessary to heat the LH/RH three-way catalytic converter joint to ease removal. Separate the LH and RH three-way catalytic converters. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2779 1. On 4.6L equipped vehicles, insert the LH three-way catalytic converter into the RH three-way catalytic converter. 2. On 5.4L equipped vehicles, insert the LH three-way catalytic converter into the RH three-way catalytic converter. 3. Position the RH and LH three-way catalytic converters and install the four nuts. 4. On 4.6L equipped vehicles, install the pipe clamp and the two nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2780 5. On 5.4L equipped vehicles, install the pipe clamp and the two nuts. 6. On 4.6L equipped vehicles, install the exhaust hanger nut. 7. On 5.4L equipped vehicles, install the exhaust hanger nut. 8. Install the transmission support crossmember. 1 Position the transmission support crossmember. 2 Install the three LH bolts and the three RH bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2781 9. Install the transmission support crossmember to transmission support insulator nuts. 10. Install the bolt. 11. Remove High-Lift Jack. 12. Connect the two Heated Oxygen Sensor (H02S) and the two Catalyst Monitor Sensor (CMS) electrical connectors. 13. Install the transfer case skid plate. 1 Position the transfer case skid plate. 2 Install the four bolts (two each side). 14. Install the muffler and tailpipe assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2782 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts 17-19 ft.lb LH Sequence --RH Sequence --Exhaust Manifold Studs 89-115 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2786 Exhaust Manifold: Testing and Inspection Special Tool 1. Place a Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side Exhaust Manifold: Service and Repair Left Side Removal All Vehicles 1. Raise and support the vehicle. 2. On 4x4 vehicles, remove the front wheel opening moulding. 3. Remove the front fender splash shield. 4. Remove the nut and the brake booster vacuum hose bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2789 5. Disconnect the Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube connections: ^ The EGR backpressure transducer hoses. ^ The EGR valve to exhaust manifold tube upper fitting. ^ The EGR valve to exhaust manifold tube lower fitting and remove the EGR valve to exhaust manifold tube. All Vehicles 6. Remove the nuts. 7. Remove the (A) nuts and the (B) exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2790 8. Remove and discard the exhaust manifold gasket. 9. Clean and inspect the exhaust manifold. Installation All Vehicles 1. Position the exhaust manifold gasket. 2. Position the (B) exhaust manifold and loosely install the (A) nuts. 3. Tighten the nuts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2791 4. Install the three-way catalytic converter to exhaust manifold nuts. 5. Connect the EGR valve to exhaust manifold tube upper fitting. ^ On 4.6L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand-tighten. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2792 ^ Stage 2: Tighten to 35 - 45 Nm (26 - 33 ft. lbs.). ^ On 5.4L engines, tighten both fittings starting at the flop in two stages. ^ Stage 1: Hand-tighten. ^ Stage 2: Tighten to 55 - 65 Nm (41 - 47 ft. lbs.). All Vehicles 6. Position the brake booster vacuum hose bracket and install the nut. 7. Install the front fender splash shield. 8. On 4x4 vehicles, install the front wheel opening moulding. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2793 Exhaust Manifold: Service and Repair Right Side Removal 1. Raise and support the vehicle. 2. On 4x4 vehicles, remove the front wheel opening moulding. 3. Remove the front fender splash shield. 4. Remove the three-way catalytic converter to exhaust manifold nuts. 5. Remove the eight (A) nuts and the (B) exhaust manifold. 6. Remove and discard the exhaust manifold gasket. 7. Clean and inspect the exhaust manifold. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 2794 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Page 2795 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Exhaust Pipe: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Exhaust Pipe: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Page 2809 Exhaust Pipe: Service and Repair For service information, refer to Muffler Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shield Bolts 10-13 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Muffler: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Muffler: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2827 Muffler: Specifications Muffler Inlet Pipe to TWC Clamp Nuts 35-46 ft.lb Muffler to Catalytic Converter Pipe Clamp Nuts 30-40 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2828 Muffler: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the muffler to Three Way Catalytic Converter (TWC) pipe clamp. 1 Remove the clamp nuts. 2 Remove the clamp. 3. NOTE: The exhaust hanger insulators can be reused if they show no signs of damage. Remove the exhaust hanger insulators and discard, if damaged. 4. Remove the tailpipe from the exhaust hanger insulator. 5. NOTE: It may be necessary to heat the TWC joint to ease removal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2829 Remove the muffler and tailpipe assembly. Installation 1. Position the muffler and tailpipe assembly. 2. CAUTION: Do not use oil or grease based lubricants, on insulators which deteriorates the rubber. NOTE: A soap and water solution will ease install action of the muffler hangers into the rubber tailpipe hanger insulators. 2. Install the exhaust hanger insulators. 3. Install the tailpipe into the exhaust hanger insulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2830 4. Install the muffler to catalytic converter pipe clamp. 1 Position the clamp. 2 Install the nuts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2842 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2843 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2844 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 2850 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 2851 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2856 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2857 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2858 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 2863 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 2869 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 2870 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 2875 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2876 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Engine Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2897 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2898 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2899 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2903 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 2906 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2911 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2912 Fuel Pump Relay: Description and Operation The Fuel Pump relay: - engages the fuel pump when energized by the powertrain control module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2913 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2914 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2918 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 2921 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2926 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2937 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2938 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2944 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2945 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 2946 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 2947 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 2948 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 2949 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2953 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2957 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2958 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2962 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2963 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2964 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation The fuel tank pressure sensor: ^ monitors the fuel tank pressure. ^ communicates the fuel tank pressure reading to the PCM during the OBD II leak test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the intake air temperature sensor electrical connector. 3. Remove the Intake Air Temperature (IAT) sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2974 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2979 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2980 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2981 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2982 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2983 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2984 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2985 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2986 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2987 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2988 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2989 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2990 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2991 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2992 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2993 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2994 Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 2997 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3014 Oxygen Sensor: Service and Repair Oxygen Sensor Wrench SPECIAL SERVICE TOOLS REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector. 4. Use the special tool to remove the Heated Oxygen Sensor (HO2S). INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3015 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3025 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3026 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3027 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3028 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3029 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3034 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3035 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3037 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3061 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3062 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3068 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3069 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3070 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3071 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3072 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3073 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Service and Repair Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector. 4. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Remove the bolts. 2 Remove the (IFS) switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3084 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3088 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3089 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3090 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3096 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3097 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3098 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3099 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3100 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3101 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 3104 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 3105 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 3106 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3110 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3116 Fuel Pressure Test Port: Description and Operation The Fuel Pressure Relief valve: ^ is used to inspect and relieve fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3117 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3125 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) Outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3136 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3137 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Description and Operation Ignition Cable: Description and Operation The spark plug wires carry high voltage pulses from the ignition coil to the spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Description and Operation > Page 3145 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. To install. reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3150 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3151 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3152 Spark Plug: Description and Operation The spark plug. ^ change the high voltage pulse from the ignition coil into a spark which ignites the fuel and air mixture. ^ are different for the LH and RH side of the engine. ^ originally equipped on the vehicle have a Platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3153 Spark Plug: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Remove the spark plugs. NOTE: Remove any foreign materials from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3154 5. Inspect for carbon fouling ^ Look for black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with a incorrect heat range, dirty air cleaner, too rich fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating identified by a white or light gray-brown spots and white bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with a incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3155 9. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3159 Compression Check: Testing and Inspection Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results Part 1 Of 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, XO-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3160 Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3173 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3174 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 3180 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine Lean Driveability Symptoms > Page 3181 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 3187 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 3193 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3194 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3195 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3196 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3197 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the intake air temperature sensor electrical connector. 3. Remove the Intake Air Temperature (IAT) sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3207 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Computers and Control Circuit Diode > Component Information > Locations Computers and Control Circuit Diode: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Computers and Control Circuit Diode > Component Information > Locations > Page 3211 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3215 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3216 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3220 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3221 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3222 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 Data Link Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Specifications EGR Backpressure Transducer: Specifications EGR Transducer Nuts 2.2-5.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Specifications > Page 3244 EGR Backpressure Transducer: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube. ^ sends an EGR flow rate signal to the powertrain control module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3253 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3254 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3255 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3261 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3262 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3267 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3268 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3269 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3274 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3280 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3281 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3286 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3287 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3298 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3299 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 Engine Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3308 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3309 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3310 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation The fuel tank pressure sensor: ^ monitors the fuel tank pressure. ^ communicates the fuel tank pressure reading to the PCM during the OBD II leak test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control (IAC) Valve Bolts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3317 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the IAC valve. 4. Remove the two bolts and the Idle Air Control (IAC) valve. 5. Remove and discard the Idle Air Control (IAC) gasket. INSTALLATION 1. To install, reverse the removal procedure. Install a new Idle Air Control (IAC) gasket. Tighten the two bolts in 2 stages. - Stage 1:10 Nm (89 lb-in) - Stage 2: Rotate 90 degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Multiplex Communication Network: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Multiplex Communication Network: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 Diagram 14-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Page 3336 Multiplex Communication Network: Description and Operation The vehicle has two module communication networks. The Standard Corporate Protocol (SCP), which is an unshielded twisted-pair cable (data bus plus, Circuit 914 [T/O] and data bus minus, Circuit 915 [PK/LB]) and the International Standards Organization (ISO) 9141 communications network, which is single-wire network (Circuit 70 [LB/W]). Both networks can be connected to New Generation STAR (NGS) Tester through one connector called the Data Link Connector (DLC). This makes diagnosing these systems easier by allowing one smart tester to be able to diagnose and test any module on the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Page 3337 two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The ISO 9141 communications network does not permit inter module communication. When NGS Tester communicates to modules on the ISO 9141 communication network, NGS Tester must ask for all information; the modules cannot initiate communications. The SCP network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+), or if some, but not all, termination resistors are lost. The PCM is the only module that contains termination resistors. Unlike the SCP network, the ISO 9141 communication network will not function if the network is shorted to ground or battery positive voltage (B +). Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. The PCM is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The Restraint Control Module (RCM) is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. The Electronic Automatic Temperature Control (EATC) module is on the SCP communication network. The EATC module controls automatic climate functions that maintain the vehicle cabin temperature at a constant setting. The Generic Electronic Module (GEM) is on the ISO 9141 communication network. The GEM controls a variety of systems: ^ windshield wipers ^ courtesy lamps ^ 4-wheel shift on the fly ^ warning chimes ^ one touch down power windows The remote anti-theft personality (RAP) module is on the ISO 9141 communication network. The RAP module controls the remote entry, interior lamp illumination signal to the GEM and panic alarm from the keyless entry remote. The anti-lock brake control module is on the ISO 9141 communication network. The module controls brake pressure to the four wheels to keep the vehicle under control while braking. The following describes the rear- and four-wheel air suspension modules: The air suspension control module is on the ISO 9141 communication network and controls the air compressor motor (through a solid state relay) and all system solenoids. The module also provides power to front and rear height sensors. The module controls vehicle height adjustments by monitoring two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing the vehicle and module. The control module is mounted in the passenger compartment inside the instrument panel above the radio and temperature controls. The air suspension control module monitors and controls the system through a 32-pin two-way connector. It is keyed so that the control module cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversal of connections. The instrument cluster is on the SCP communication network. The instrument cluster is also called a Hybrid Electronic Cluster (HEC). It is an analog face cluster with a digital odometer. The instrument cluster displays a variety of information. The instrument cluster now includes the Passive Anti-theft System (PATS) software internally. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis Multiplex Communication Network: Flow of Diagnosis 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Fuse junction panel Fuse 3 (20 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Electronic Automatic Temperature Control (EATC) module ^ Driver Seat Module (DSM) ^ Remote Anti-theft Personality (RAP) module ^ Generic Electronic Module (GEM) ^ Restraint Control Module (RCM) ^ Powertrain Control Module (PCM) ^ Air suspension control module ^ Anti-lock brake control module ^ Instrument cluster 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/M: No Module /Network Communication - No Power To NGS 4. Go to Pinpoint Test PC. See: Initial Inspection and Diagnostic Overview/System Precheck Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3340 Multiplex Communication Network: Initial Inspection and Diagnostic Overview PC1 Inspection and Verification (Start Here) 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Fuse junction panel Fuse 3 (20 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Electronic Automatic Temperature Control (EATC) module ^ Driver Seat Module (DSM) ^ Remote Anti-theft Personality (RAP) module ^ Generic Electronic Module (GEM) ^ Restraint Control Module (RCM) ^ Powertrain Control Module (PCM) ^ Air suspension control module ^ Anti-lock brake control module ^ Instrument cluster 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3341 ^ Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/M: No Module /Network Communication - No Power To NGS 4. Go to Pinpoint Test PC. See: System Precheck Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3342 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3343 Multiplex Communication Network: Pinpoint Tests Pinpoint Test Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3344 A1 - A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3345 A3 - A5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3346 B1 - B3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3347 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3348 C1 - C3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3349 D1 - D2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3350 D3 E1 - E2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3351 E3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3352 F1 - F3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3353 F4 - F5 G: Powertrain Control Module (PCM) Does Not Respond To NGS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3354 G1 - G2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3355 G3 - G4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3356 G5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3357 H1 - H2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3358 H3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3359 J1 - J2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3360 J3 K: No Module/ Network Communication - SCP Network Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3361 K1 - K2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3362 K3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3363 K4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3364 K5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3365 K6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3366 K7 L: No Module/ Network Communication - ISO 9141 Network Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3367 L1 - L2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3368 L3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3369 L4 - L5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3370 L6 - L7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3371 L8 - L9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3372 L10 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3373 L11 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3374 M1 - M2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3375 M3 - M4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3376 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3377 Multiplex Communication Network: Service and Repair Communication Circuit Wiring Repair Heat Gun SPECIAL SERVICE TOOLS 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. 4. Bend the wires back in a straight line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3378 NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair, ^ Overlap the heat shrink tube on both wires. 6. Use Heat Gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3382 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3386 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 3389 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3397 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3398 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3399 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3401 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3402 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3404 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3405 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3406 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3407 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3408 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3409 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3410 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3411 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3412 Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3415 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3432 Oxygen Sensor: Service and Repair Oxygen Sensor Wrench SPECIAL SERVICE TOOLS REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector. 4. Use the special tool to remove the Heated Oxygen Sensor (HO2S). INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3433 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3446 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3447 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3448 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3454 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3455 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3460 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3461 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3462 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3467 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3473 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3474 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3479 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3480 Engine Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3493 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3496 Engine Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3497 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3501 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3502 Engine Control Module: Removal and Replacement REMOVAL 1. Disconnect the battery ground cable. 2. Loosen the bolt and disconnect the electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3503 6. Remove the Powertrain Control Module (PCM). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3507 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 3510 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3520 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3521 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3527 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3528 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 3534 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 3535 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3540 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3541 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3542 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 3548 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 3549 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3554 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3555 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3556 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3557 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3558 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3559 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3560 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3564 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3568 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Ford service procedures identify a Coolant Temperature sensor for this engine. However, in the powertrain wiring diagram, a component labeled Cylinder Head Temperature (CHT) sensor is indicated. Ford does not provide an image location or service procedure for a Cylinder Head Temperature (CHT) sensor on this vehicle/engine combination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3569 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Engine Coolant Temperature (ECT) sensor. 3. Remove the engine coolant temperature sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3573 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3574 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3575 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation The fuel tank pressure sensor: ^ monitors the fuel tank pressure. ^ communicates the fuel tank pressure reading to the PCM during the OBD II leak test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the intake air temperature sensor electrical connector. 3. Remove the Intake Air Temperature (IAT) sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3585 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3590 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3591 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3592 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3593 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3594 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3595 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3596 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3597 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3598 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3599 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3600 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3601 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3602 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3603 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3604 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3605 Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3608 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3625 Oxygen Sensor: Service and Repair Oxygen Sensor Wrench SPECIAL SERVICE TOOLS REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the electrical connector. 4. Use the special tool to remove the Heated Oxygen Sensor (HO2S). INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3626 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3636 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3637 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3638 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3639 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3640 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3647 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3648 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3649 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3650 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3651 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3665 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3666 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3667 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3668 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3669 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3675 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3676 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3677 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3678 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3693 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3694 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3695 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3696 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3700 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3701 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3702 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3703 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3704 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3705 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3706 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3707 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3708 Catalytic Converter: Specifications Three Way Catalytic Converter to Exhaust Manifold Nuts 25-33 ft.lb Exhaust Converter Frame Bracket to Catalytic Converter Pip Nuts 25-33 ft.lb LH to RH Catalytic Converter Pipe Clamp Nuts 35-46 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3709 Catalytic Converter: Service and Repair Removal 1. Remove the muffler and tail pipe assembly. 2. Disconnect the two Heated Oxygen Sensors (H02S) and the two Catalyst Monitor Sensor (CMSs) connectors. 3. Remove the nuts. 4. Remove the transfer case skid plate. 1 Remove the four bolts. 2 Remove the transfer case skid plate. 5. Remove the bolt. 6. Use High-Lift Jack to support the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3710 7. Remove the transmission support crossmember to transmission support insulator nuts. 8. Remove the transmission support crossmember. 1 Remove the three LH bolts and the three RH bolts. 2 Remove the transmission support crossmember. 9. On 4.6L equipped vehicles, remove the exhaust hanger nut. 10. On 5.4L equipped vehicles, remove the exhaust hanger nut. 11. Remove the two three-way catalytic converters. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3711 12. On 4.6L equipped vehicles, if only one Three-Way Catalytic Converter (TWC) is being replaced, remove clamp. 13. NOTE: It may be necessary to heat the LH/RH three-way catalytic converter joint to ease removal. Separate the LH and RH three-way catalytic converters. 14. On 5.4L equipped vehicles, if only one three-way catalytic converter is being replaced, remove the clamp. 15. NOTE: It may be necessary to heat the LH/RH three-way catalytic converter joint to ease removal. Separate the LH and RH three-way catalytic converters. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3712 1. On 4.6L equipped vehicles, insert the LH three-way catalytic converter into the RH three-way catalytic converter. 2. On 5.4L equipped vehicles, insert the LH three-way catalytic converter into the RH three-way catalytic converter. 3. Position the RH and LH three-way catalytic converters and install the four nuts. 4. On 4.6L equipped vehicles, install the pipe clamp and the two nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3713 5. On 5.4L equipped vehicles, install the pipe clamp and the two nuts. 6. On 4.6L equipped vehicles, install the exhaust hanger nut. 7. On 5.4L equipped vehicles, install the exhaust hanger nut. 8. Install the transmission support crossmember. 1 Position the transmission support crossmember. 2 Install the three LH bolts and the three RH bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3714 9. Install the transmission support crossmember to transmission support insulator nuts. 10. Install the bolt. 11. Remove High-Lift Jack. 12. Connect the two Heated Oxygen Sensor (H02S) and the two Catalyst Monitor Sensor (CMS) electrical connectors. 13. Install the transfer case skid plate. 1 Position the transfer case skid plate. 2 Install the four bolts (two each side). 14. Install the muffler and tailpipe assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3715 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Evaporative Emission Canister Purge Valve Bolts 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3720 Canister Purge Control Valve: Description and Operation The evaporative emission canister purge valve: ^ regulates purging of the evaporative emissions canister. ^ is controlled by the powertrain control module. ^ contains EVAP test port. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3721 Canister Purge Control Valve: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. 1. Disconnect the EVAP canister purge valve electrical connector and the evaporative emissions vacuum control hose. 2. Disconnect the two fuel vapor tubes. 1 Disconnect the EVAP canister purge outlet tube. 2 Disconnect the evaporative emission return tube. 3. Remove the bolts and remove the valve. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3722 1. Follow the removal procedure in reverse order. 2. Leak Test the system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Canister Assembly Leak Test 3. Perform the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Description and Operation Canister Purge Volume Control Valve: Description and Operation The evaporative emissions canister vent valve: ^ seals the evaporative emissions systems for the OBD II leak test. ^ is mounted on the evaporative emissions canister. ^ is serviced as a separate item. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative Emissions Canister Nuts 15-20 Nm Evaporative Emissions Canister Brackets 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3729 Evaporative Emission Control Canister: Description and Operation The evaporative emissions canister: ^ is located along the left frame rail behind the fuel tank. ^ contains activated carbon. ^ stores fuel vapors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3730 Evaporative Emission Control Canister: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS MAY BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the Evaporative Emissions Canister Vent Solenoid electrical connector. 3. Loosen the clamp and remove the Evaporative Emission Purge Outlet Tube. 4. Remove the nuts and remove canister and bracket assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3731 5. If required, remove the Evaporative Emissions Canister (EVAP canister). 1 Remove the bolt. 2 Remove the bracket. 6. If required, remove the retainer. ^ Slide the retainer off the bracket. 7. Remove the evaporative emissions canister vent solenoid. NOTE ^ Inspect and replace the O-ring as necessary. ^ A twisting and pulling motion is required to remove the evaporative emissions canister vent solenoid. 8. Remove canister inlet fitting. NOTE ^ Inspect and replace the O-ring as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3732 ^ If required, a twisting and pulling motion is required to remove the inlet fitting. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE ^ If equipped with air suspension, reactivate the system by turning on the air suspension switch. ^ Lubricate the O-ring seals with ESE-M99B144-B "MerPol" or equivalent. 2. Leak Test the system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Canister Assembly Leak Test 3. Perform the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Specifications EGR Backpressure Transducer: Specifications EGR Transducer Nuts 2.2-5.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Specifications > Page 3737 EGR Backpressure Transducer: Description and Operation The EGR transducer: ^ monitors the EGR flow rate through the EGR valve to exhaust manifold tube. ^ sends an EGR flow rate signal to the powertrain control module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications Exhaust Gas Recirculation Vacuum Regulator Bracket Bolt And Nut 8-12 Nm EGR Vacuum Regulator Solenoid Nuts 2.5-5.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3741 EGR Electronic Vacuum Regulator Solenoid: Description and Operation The EGR Vacuum Regulator Solenoid uses input from the Powertrain Control Module to change the EGR valve operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3742 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Remove the EGR vacuum regulator solenoid. 1 Disconnect the vacuum hose. 2 Disconnect the electrical connector. 3 Remove the nuts. 4 Remove the EGR vacuum regulator solenoid. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair REMOVAL 1. Remove the EGR valve to exhaust manifold tube. 1 Remove the two EGR transducer tubes. 2 Remove the EGR valve to exhaust manifold tube upper fitting. 3 Remove the (A) EGR valve to exhaust manifo1d lower tube fitting and the (B) EGR valve to exhaust manifold tube. NOTE: The 4.6L Engine shown; the 5.4L engine is similar. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 8-11.5 Nm EGR Valve To Exhaust Manifold Tube Fittings 34-47 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3749 EGR Valve: Description and Operation The EGR valve to exhaust manifold tube: ^ connects the exhaust manifold to the EGR valve. ^ has two tubes connecting to the EGR transducer for EGR flow monitoring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3750 EGR Valve: Service and Repair REMOVAL 1. Disconnect the EGR valve vacuum hose. 2. Remove the (A) nut and the (B) brake booster tube bracket. 3. Disconnect the EGR valve-to-exhaust manifold tube upper fitting. 4. Remove the EGR valve (EGR valve). 1 Remove the bolts. 2 Remove the EGR valve and the EGR valve gasket. Discard the EGR valve gasket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3751 1. Follow the removal procedure in reverse order. NOTE: Install a new EGR valve gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold PCV Valve Hose: Customer Interest Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3764 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3765 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold PCV Valve Hose: All Technical Service Bulletins Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3771 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3772 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold Positive Crankcase Ventilation Valve: Customer Interest Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3781 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Customer Interest for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3782 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold Positive Crankcase Ventilation Valve: All Technical Service Bulletins Engine - High Idle and Sticking Throttle When Cold Article No. 01-21-12 10/29/01 ^ IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES ---- VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 EQUIPPED WITH 5.4L ENGINE ^ ENGINE - 5.4L - PCV SYSTEM ICING - VEHICLES BUILT 12/2/1997 THROUGH 7/15/1999 ONLY FORD: 1998-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1999 NAVIGATOR This article is being republished in its entirety to update the Service Procedure, Service Parts and the model years involved. ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the Positive Crankcase Ventilation (PCV) gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the revised PCV service parts, PCV valve YC2Z-6K773-AA, and hose, YL3Z-8A505-BA. To Install The Heated PCV Valve, Use The Following Procedure: 1. Partially drain off enough coolant into a clean, suitable container to allow hose disassembly at the top of the engine, approximately 3.8L - 7.5L (1-2 gallons) and save coolant. 2. Remove the PCV valve by disconnecting the vent hose and removing the valve from the valve cover grommet. Ensure the area is clean to prevent dirt entry into engine. 3. Install the new, heated PCV valve in the valve cover grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3788 4. Disconnect the Engine Coolant Temperature (ECT) Sensor coolant supply hose from the throttle body (Figure 1). 5. Reconnect the ECT Sensor coolant supply hose to PCV valve heated fitting (use nipple that points nearly horizontal, Figure 2). 6. Install and connect the new hose from the heated PCV valve fitting (points nearly upward, Figure 2) to the throttle body fitting where the ECT Sensor coolant supply hose was disconnected. 7. Refill the system with the drained off coolant, bleed system, and check level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Positive Crankcase Ventilation Valve: > 01-21-12 > Oct > 01 > Engine - High Idle and Sticking Throttle When Cold > Page 3789 Parts Block OTHER APPLICABLE ARTICLES: 01-21-5 SUPERSEDES: 99-25-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012112A Inspect And Replace PCV 0.6 Hr. System With Updated Parts DEALER CODING CONDITION BASIC PART NO. CODE 6K773 42 OASIS CODES: 401000, 607400, 607500, 607600, 607700, 608400, 608500, 608600, 609400, 609500, 609600, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 612600, 614500, 614600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Page 3790 Positive Crankcase Ventilation Valve: Description and Operation LH Component Location RH Component The PCV valve: ^ controls the amount of ventilating air and blow-by gases going to the intake manifold. ^ prevents a backfire from reaching the crankcase. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the EGR transducer. 1 Remove the EGR transducer hoses. 2 Disconnect the EGR transducer electrical connector. 3 Remove the nuts. 4 Remove the EGR transducer. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3800 Fuel Pressure Test Port: Description and Operation The Fuel Pressure Relief valve: ^ is used to inspect and relieve fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3801 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 680 - 830 RPM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal: > 99-18-12 > Sep > 99 > Accelerator Pedal - Vibrates Accelerator Pedal: Customer Interest Accelerator Pedal - Vibrates Article No. 99-18-12 09/06/99 ^ ENGINE - 4.6L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ ENGINE - 5.4L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ VIBRATION - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 AND WITH 4.6L OR 5.4L 2-VALVE ENGINE FORD: 1999 EXPEDITION LINCOLN: 1999 NAVIGATOR This TSB article is being republished in its entirety to provide engine applications. ISSUE A vibration may be felt in the accelerator pedal on some vehicles. This may be caused by the accelerator cable contacting the power steering reservoir. ACTION Replace accelerator cable with a revised cable and a new routing. The revised cable and routing should reduce the possibility of feeling vibration through the accelerator pedal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the accelerator cable following the procedure outlined in the 1999 Expedition/Navigator Workshop, Section 310-02. 2. Install revised Accelerator Cable (XL1Z-9A758-EA) following the removal procedure in reverse order. Route the cable outboard of the power Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal: > 99-18-12 > Sep > 99 > Accelerator Pedal - Vibrates > Page 3816 steering reservoir and clip to the speed control cable (Figure 1). NOTE MAKE SURE CABLE IS NOT TOUCHING THE POWER STEERING RESERVOIR OR THE BRAKE BOOSTER VACUUM HOSE. PART NUMBER PART NAME XL1Z-9A758-EA Accelerator Cable OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991812A Install Revised Accelerator 0.4 Hr. Cable DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 OASIS CODES: 497000, 499000, 703000, 703200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > 99-18-12 > Sep > 99 > Accelerator Pedal - Vibrates Accelerator Pedal: All Technical Service Bulletins Accelerator Pedal - Vibrates Article No. 99-18-12 09/06/99 ^ ENGINE - 4.6L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ ENGINE - 5.4L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ VIBRATION - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 AND WITH 4.6L OR 5.4L 2-VALVE ENGINE FORD: 1999 EXPEDITION LINCOLN: 1999 NAVIGATOR This TSB article is being republished in its entirety to provide engine applications. ISSUE A vibration may be felt in the accelerator pedal on some vehicles. This may be caused by the accelerator cable contacting the power steering reservoir. ACTION Replace accelerator cable with a revised cable and a new routing. The revised cable and routing should reduce the possibility of feeling vibration through the accelerator pedal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the accelerator cable following the procedure outlined in the 1999 Expedition/Navigator Workshop, Section 310-02. 2. Install revised Accelerator Cable (XL1Z-9A758-EA) following the removal procedure in reverse order. Route the cable outboard of the power Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > 99-18-12 > Sep > 99 > Accelerator Pedal - Vibrates > Page 3822 steering reservoir and clip to the speed control cable (Figure 1). NOTE MAKE SURE CABLE IS NOT TOUCHING THE POWER STEERING RESERVOIR OR THE BRAKE BOOSTER VACUUM HOSE. PART NUMBER PART NAME XL1Z-9A758-EA Accelerator Cable OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991812A Install Revised Accelerator 0.4 Hr. Cable DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 OASIS CODES: 497000, 499000, 703000, 703200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Page 3823 Accelerator Pedal: Specifications Accelerator Pedal and Shaft Bolts 10 Nm Accelerator Control Splash Shield Bolts 5.9-8.1 Nm Accelerator Cable Bracket Bolts 6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions Accelerator Pedal: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3832 Accelerator Pedal: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3839 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3840 Accelerator Pedal: Electrical Diagrams Diagram 127-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3841 Diagram 127-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 Diagram 127-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Page 3843 Accelerator Pedal: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable, or interfere with the accelerator pedal and shaft. The vehicle is also available with an adjustable pedals option. This allows both the accelerator and brake pedals to be adjusted simultaneously forward or rearward. A rocker switch on the instrument panel provides adjustment on the pedals assembly when it is activated. On vehicles with the memory seat option, the pedals position can be controlled by the memory selection, as well as the rocker switch. The accelerator pedal and shaft can still be serviced separately on the adjustable pedals assembly. The components in the acceleration control system are not adjustable and must be replaced if damaged or worn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis Accelerator Pedal: Flow of Diagnosis 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft ^ Damaged linkage ^ Damaged accelerator cable ^ High engine idle speed ^ Damaged throttle body ^ Damaged or binding adjustable pedal assembly 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3846 Accelerator Pedal: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft ^ Damaged linkage ^ Damaged accelerator cable ^ High engine idle speed ^ Damaged throttle body ^ Damaged or binding adjustable pedal assembly 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3847 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal Accelerator Pedal: Service and Repair Accelerator Pedal REMOVAL 1. Disconnect the (A) accelerator cable from the (B) accelerator pedal and shaft. 2. Remove the bolts and remove the accelerator pedal and shaft. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal > Page 3850 Accelerator Pedal: Service and Repair Accelerator Cable Bracket REMOVAL 1. Remove the left hand side accelerator control splash shield bolts. 2. Remove the right hand side accelerator control splash shield bolt and remove the splash shield. 3. Disconnect the speed control cable. 4. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever forward. ^ Slide the accelerator cable end from the throttle lever. 5. Depress the locking tabs and remove the accelerator cable from the accelerator cable bracket. 6. Remove the spring from the accelerator cable bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal > Page 3851 7. Remove the bolts and remove the accelerator cable bracket. NOTE: For clarity, the air intake duct is not shown in this illustration. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal > Page 3852 Accelerator Pedal: Service and Repair Pedal - Adjustable REMOVAL 1. Depress the locking tabs on the accelerator pedal drive cable and remove the drive cable from the accelerator pedal assembly. NOTE: Make sure that the adjustable pedals assembly is at the full forward position (pedals positioned toward front of the vehicle). The accelerator pedal and shaft can be serviced separately from the adjustable pedal assembly. However, the accelerator pedal and shaft itself is only serviced as an assembly. 2. Disconnect the accelerator cable from the accelerator pedal and shaft assembly. 3. Remove the bolts and remove the accelerator pedal and shaft assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal > Page 3853 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3858 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) Outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3870 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3871 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3877 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3878 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3879 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3881 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3882 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 3887 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3888 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3897 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3898 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3899 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3900 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3901 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3907 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3908 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3909 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3910 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3911 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 3917 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 3918 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 3924 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 3925 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 3926 Fuel Filler Cap: Description and Operation The fuel tank filler cap: ^ relieves system pressure above 14 kPa (2 psi). ^ relieves system vacuum negative 3.8 kPa (0.53 psi). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair EFI/CFI Fuel Pressure Gauge SPECIAL SERVICE TOOLS REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the wiring splash shield. 3. Loosen tie bolt and disconnect the 42 pin engine bulkhead connector. 4. Disconnect the (A) fuel charging wiring electrical connector from the (B) engine control sensor wiring electrical connector. NOTE: The (A) fuel charging wiring electrical connector and the (B) engine control sensor wiring electrical connector are located behind the (C) mount. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3935 5. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 6. Disconnect the Intake Manifold Tuning Valve (IMTV). NOTE: The Generator (GEN) is removed for clarity. 7. Disconnect the following electrical connectors: ^ LH ignition coil connector (A). ^ Camshaft Position (CMP) sensor electrical connector (B). ^ Radio capacitor electrical connector (C). 8. Disconnect the following electrical connectors. ^ RH ignition coil electrical connector (A). ^ Radio capacitor electrical connector (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3936 9. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 10. Disconnect the following electrical connectors: ^ Idle Air Control (IAC) valve electrical connector (A). ^ Differential Pressure Feedback Exhaust Gas Recirculation (EGR) transducer electrical connector (B). ^ Exhaust Vacuum Regulator (EVR) electrical connector (C). ^ Throttle Position (TP) sensor electrical connector (D). 11. Disconnect the following electrical connectors: ^ Disconnect the (A) Engine Coolant Temperature (ECT) sensor electrical connector. ^ Disconnect the (B) water temperature indicator sender unit electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3937 12. Disconnect the RH fuel injector electrical connectors. 13. Disconnect the LH fuel injector electrical connectors. 14. Raise the vehicle. 15. Disconnect the A/C compressor clutch electrical connector. NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well. 16. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 17. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3938 18. Disconnect the oil pressure sending unit electrical connector. 19. Disconnect the Electronic Variable Orifice (EVO) electrical connector. 20. Lower the vehicle. 21. Remove the fuel charging wiring. INSTALLATION 1. Position the fuel charging wiring on the engine. 2. Raise the vehicle. 3. Connect the oil pressure sending unit electrical connector. 4. Connect the EVO electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3939 5. Connect the CKP sensor electrical connector. 6. Connect the HO2S electrical connectors. 7. Connect the A/C compressor clutch electrical connector. 8. Lower the vehicle. 9. Connect the LH fuel injector electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3940 10. Connect the RH fuel injector electrical connectors. 11. Connect the engine cooling system sensor connections. ^ Connect the (A) ECT sensor electrical connector. ^ Connect the (B) water temperature indicator sender unit electrical connector. 12. Connect the following electrical connectors: ^ LAC valve electrical connector (A). ^ Differential pressure feedback EGR transducer electrical connector (B). ^ EVR electrical connector (C). ^ TP sensor electrical connector (D). 13. Connect tie following electrical connections: ^ LH ignition coil connector (A). ^ CMP electrical connector (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3941 ^ Radio capacitor electrical connector (C). 14. Connect the following electrical connectors. ^ RH ignition coil electrical connector (A). ^ Radio capacitor electrical connector (B). 15. Connect the IMTV electrical connector. NOTE: The generator is removed for clarity. 16. Connect the IAT sensor electrical connectors. 17. Connect the (A) fuel charging wiring electrical connector to the (B) engine control sensor wiring electrical connector. NOTE: The (A) fuel charging wiring electrical connector and the (B) engine control sensor wiring electrical connector are located behind the (C) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 3942 mount. 18. Connect the engine bulkhead connector. 19. Install the wiring splash shield. 20. Install the accelerator control splash shield. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting Fuel Line Coupler: Service and Repair Hairpin Clip Fitting REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. the use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Remove the shipping tab by bending it downward. 2. Spread the hairpin Clip legs and push the clip into the fitting. 3. Separate the fitting from the tube. INSTALLATION 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-F to the male tube end. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 3947 3. Insert the hairpin clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube in the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 3948 Fuel Line Coupler: Service and Repair Spring Lock Coupling SPECIAL SERVICE TOOLS DISCONNECT WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the fuel tube clip. 3. Install the Disconnect Tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 3949 4. Close and push the Disconnect Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Disconnect Tool. CONNECT 1. Follow the removal procedure in reverse order. ^ Inspect and clean both the coupling ends. ^ Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-F. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 3950 Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Disconnect Tool SPECIAL SERVICE TOOLS DISCONNECT WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Perform the Fuel Pressure Release Procedure. 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push into the fitting. 4. Separate the fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 3951 ^ Inspect for damage. ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push it until a click is heard. NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-F to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 3952 Fuel Line Coupler: Service and Repair Vapor Tube Fitting REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. INSTALLATION 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation The Fuel Pressure Regulator: ^ maintains a constant fuel pressure throughout the fuel system and to the fuel injectors. ^ is spring-loaded and operated by the intake manifold vacuum. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3956 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the fuel pressure regulator. 1 Disconnect the vacuum hose. 2 Remove the snap ring. 3 Remove the fuel pressure regulator. 3. Remove and discard the fuel pressure regulator O-rings. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-rings that are made of special fuel resistant material Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings. NOTE: Lubricate the new O-rings with clean engine oil, XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 3960 Fuel Pressure Test Port: Description and Operation The Fuel Pressure Relief valve: ^ is used to inspect and relieve fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 3961 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3967 Fuel Pressure Test Port: Description and Operation The Fuel Pressure Relief valve: ^ is used to inspect and relieve fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3968 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Perform the Fuel Pressure Release Procedure. 2. Remove the (A) fuel pressure relief valve with the (B) fuel pressure relief valve cap. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3972 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3973 Fuel Pump Relay: Description and Operation The Fuel Pump relay: - engages the fuel pump when energized by the powertrain control module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3974 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3975 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Injection Supply Manifold Bolts 8-11 Nm Brake Booster Bracket Nuts 8.9-12.1 Nm 42 Pin Engine Control Sensor Wiring Electrical Connector Bolt 4-5.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3979 Fuel Rail: Description and Operation The Fuel Injection Supply Manifold: ^ delivers fuel to the individual fuel injectors. ^ receives fuel from the fuel supply line. ^ returns unused fuel to the fuel tank return line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3980 Fuel Rail: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Perform the Fuel Pressure Release Procedure. 3. Partially drain the cooling system. 4. Remove the power steering fluid reservoir bracket. 1 Remove the bolts. 2 Position the power steering fluid reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. 7. Disconnect the fuel lines. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3981 8. Disconnect the RH fuel injector electrical connector. 9. Disconnect the LH fuel injector electrical connectors. 10. Disconnect the water heater inlet tube hose. 1 Release and move the hose clamp. 2 Disconnect the water heater inlet tube hose and position aside. 11. Remove the brake booster bracket and tube. 1 Remove the nut. 2 Release and move the two hose clamps. 3 Remove the brake booster tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3982 12. Remove the Positive Crankcase Ventilation (PCV) hose. 13. Disconnect the Exhaust Gas Recirculation (EGR) connections. ^ Two Differential Pressure Feedback (DPFE) transducer hoses (B). ^ EGR valve to exhaust manifold tube upper fitting (A). ^ EGR valve to exhaust manifold tube lower fitting and remove the EGR exhaust tube (C). 14. Disconnect the EGR valve vacuum hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3983 15. Disconnect the Vapor Management Valve (VMV) hose. 16. Remove the four bolts and lift the fuel injection supply manifold and injectors upward out of intake manifold. 17. Remove the fuel injectors from the Fuel Injection Supply Manifold. 18. Inspect the two O-rings from each fuel injector. Install new O-rings as needed. INSTALLATION 1. Install fuel injectors into the Fuel Injection Supply Manifold. NOTE: Lubricate the new O-rings with clean engine oil, XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3984 2. Install the four bolts. 3. Connect the (VMV) hose. 4. Connect the (EGR) valve hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3985 5. Connect the EGR connections: ^ Two differential pressure feedback transducer hoses.(A). ^ EGR valve to exhaust manifold tube upper fitting (B). ^ EGR valve to exhaust manifold tube lower fitting (C). 6. Install the PCV hose. 7. Install the brake booster bracket and tube. 1 Install the brake booster tube. 2 Install the two hose clamps. 3 Install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3986 8. Connect the water heater inlet tube hose. 1 Connect the water heater inlet tube hose to inlet tube. 2 Slide clamp into position. 9. Connect the LH fuel injector electrical connectors. 10. Connect the RH fuel injector electrical connectors. 11. Connect the fuel lines. 12. Connect the fuel pressure regulator vacuum hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3987 13. Install the accelerator control splash shield. 14. Install the power steering oil reservoir bracket. 15. Connect the battery ground cable. 16. Refill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > NHTSA98V312000 > Dec > 98 > Recall 98V312000: Fuel line Assemblies, Leaks Fuel Return Line: Recalls Recall 98V312000: Fuel line Assemblies, Leaks Vehicle Description: Sport utility vehicles. The fuel line assemblies may have been damaged by the supplier during manufacturing, allowing leakage. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will inspect these vehicles and, if necessary, replace the front and rear fuel line assemblies. Owner notification is expected to begin January 3, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks Technical Service Bulletin # 98S35 Date: 981201 Recall - Fuel Line Damage/Leaks SAFETY RECALL 98535 Certain 1999 Expedition and Navigator Vehicles Front and Rear Fuel Line Inspection ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment III ^ Technical Information ^ Attachment IV ^ New Part Procurement Process of Low Volume Recalls ^ Attachment V ^ Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4001 Attachment I - Administrative Information OASIS Owners will receive a notification letter that instructs them to call a toll-free number to arrange for parts to be shipped to the dealer of their choice. If it is necessary, use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1 00 per vehicle. You must contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number, identify Safety Recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER-OWNER CONTRACT You are requested to contact the owner and arrange for this service. Please note that our Coordination Center will advise owners that they will hear from you within the next two business days. (For more information, see attached copy of "Low Volume Announcement Letter" dated December 18, 1995. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment V to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4002 -- cannot be contacted -- does not make a service date CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 & 6. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment V. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information CUSTOMER VEHICLES: Parts will be shipped to your dealership according to the procedures established for "Low Volume Recalls or Owner Notification Programs". DO NOT order parts, except for dealer stock units (Refer to the attached All-Dealer letter). NOTE: When the customer calls the Coordination Center, the correct parts will be automatically sent to the Dealer. This will avoid having the customer return to the dealer if the vehicle fails the inspection. Parts not used may be returned for credit. (See "Excess Stock Return" below). STOCK VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4003 Correct all vehicles in stock before delivery. First, inspect all affected stock vehicles to determine parts requirements. Then, contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts. When calling this number, identify recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: 1999 EXPEDITION AND NAVIGATOR INSPECTION 1. Raise and support the vehicle. 2. Locate the build label on the front fuel supply line. The label is located just forward of the fuel filter. Refer to Figure 1. ^ If the build label is missing, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". 3. Using a shop towel, clean the label as necessary. 4. Check the month and day codes of the build label. See Figure 1. ^ If the fuel line build label has a build date code of August 21 ( H 21) or earlier, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4004 ^ If the fuel line has a build date code of August 22 ( H 22) or later, no service action is required. Return the vehicle to the customer. SERVICE PROCEDURE 1. Open the hood. 2. Remove the jack handle from the radiator support. WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 3. Relieve fuel system pressure as follows: ^ Remove the schrader valve cap and attach the EFI/CFI fuel pressure gauge. ^ Slowly open the manual valve on EFI/CFI fuel pressure gauge to relieve the fuel pressure. ^ Remove the fuel pressure gauge and reinstall the schrader valve. 4. Turn off the air suspension switch, located under the right side of the instrument panel, if equipped. 5. Install the memory saver, then disconnect the battery negative cable. 6. Disconnect both of the fuel lines from the fuel manifold. 7. Raise and support the vehicle. 8. Completely drain the fuel tank into appropriate container. 9. On 4 x 4 models, remove the transfer case skid plate, if equipped. 10. On 4 x 4 models, reposition the front driveshaft as follows: ^ Place an alignment mark on the driveshaft mounting flange and front axle flange. ^ Remove the driveshaft mounting flange retaining bolts. ^ Swing the driveshaft down and under the engine oil pan. This will allow access to the front fuel line clip. 11. On 4 x 4 models equipped with 4.6L engines, remove the CMS sensor Christmas tree fastener from the bracket at the rear of the transmission. 12. Disconnect the front fuel return line from the rear fuel return line. Connection is located near the fuel filter. 13. Disconnect the front fuel supply line from the fuel filter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4005 14. Unclip both of the front fuel lines from the back clip. See Figure 2. 15. Unclip both of the front fuel lines from the middle clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4006 16. Using the jack handle removed previously, unclip both of the front fuel lines from the front clip. See Figure 3. A 24 to 28-inch flat screwdriver will work instead of the jack handle. 17. Remove both of the front fuel lines from the vehicle. 18. Transfer the safety clips used on the fuel manifold connections, to the new front fuel lines. 19. On 4 x 4 models, remove the fuel filter from its mounting bracket and reposition it below the frame rail. 20. Disconnect the rear fuel supply line from the fuel filter. 21. On 4 x 4 models, install the fuel filter back into its mounting bracket. 22. Position an adjustable jack under the fuel tank. Raise the jack to support the fuel tank. 23. Remove the fuel tank straps. On 4 x 4 models, the skid plate and the fuel tank straps are riveted together. 24. Disconnect the fuel filler hose from the fuel tank. 25. Lower the fuel tank approximately 15 cm (6 in). On 4 x 4 models, lower the skid plate and fuel tank as an assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4007 26. Disconnect both of the rear fuel lines from the fuel pump. Refer to Figure 4. 27. Unclip both of the rear fuel lines from the back clip. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4008 28. Unclip both of the rear fuel lines from the front clip. See Figure 5. 29. Remove both of the rear fuel lines from the vehicle. 30. Position the new rear fuel supply line (blue convolute) on the vehicle. 31. Clip the rear fuel supply line in the front and back clips. 32. Position the new rear fuel return line (gray convolute) on the vehicle. 33. Clip the rear fuel return line in the front and back clips. 34. Connect the rear fuel lines to the fuel pump. Reattach the safety clips. 35. Raise the fuel tank to the installed position. 36. Install the fuel tank straps. Tighten the retaining bolts to 55 Nm (40 lb-ft). 37. Remove the adjustable jack. 38. Connect the fuel filler hose to the fuel tank. 39. Connect the rear fuel supply line to the fuel filter. Reattach the safety clip. 40. Position the front fuel supply line on the vehicle. 41. Clip the front fuel supply line in the front, middle and back clips. 42. Connect the front fuel supply line to the fuel filter. Reattach the safety clip. 43. Position the front fuel return line on the vehicle. 44. Clip the front fuel return line in the front, middle and back clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4009 45. Connect the front fuel return line to the rear fuel return line. Reattach the safety clip. 46. On 4 x 4 models, install the front driveshaft as follows: ^ Aligning the marks made previously, position the front driveshaft on the front axle flange. ^ Install the driveshaft mounting flange retaining bolts. Tighten the bolts to 103 Nm (76 lb-ft). 47. On 4 x 4 models, install the transfer case skid plate. Tighten the retaining bolts to 15 Nm (11 lb-ft). 48. Lower the vehicle. 49. Connect both of the fuel lines to the fuel manifold. Reattach the safety clip. 50. Install the jack handle on the radiator support. 51. Replace the fuel that was drained during step number 8. 52. Connect the battery negative cable, then remove the memory saver. 53. Turn the ignition key to the ON position to pressurize the fuel system. Check the fuel lines for leaks and repair as necessary. 54. Turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4010 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4011 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4012 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4013 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4014 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4015 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > NHTSA98V312000 > Dec > 98 > Recall 98V312000: Fuel line Assemblies, Leaks Fuel Return Line: All Technical Service Bulletins Recall 98V312000: Fuel line Assemblies, Leaks Vehicle Description: Sport utility vehicles. The fuel line assemblies may have been damaged by the supplier during manufacturing, allowing leakage. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will inspect these vehicles and, if necessary, replace the front and rear fuel line assemblies. Owner notification is expected to begin January 3, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks Technical Service Bulletin # 98S35 Date: 981201 Recall - Fuel Line Damage/Leaks SAFETY RECALL 98535 Certain 1999 Expedition and Navigator Vehicles Front and Rear Fuel Line Inspection ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment III ^ Technical Information ^ Attachment IV ^ New Part Procurement Process of Low Volume Recalls ^ Attachment V ^ Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4025 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4026 Attachment I - Administrative Information OASIS Owners will receive a notification letter that instructs them to call a toll-free number to arrange for parts to be shipped to the dealer of their choice. If it is necessary, use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1 00 per vehicle. You must contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number, identify Safety Recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER-OWNER CONTRACT You are requested to contact the owner and arrange for this service. Please note that our Coordination Center will advise owners that they will hear from you within the next two business days. (For more information, see attached copy of "Low Volume Announcement Letter" dated December 18, 1995. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment V to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4027 -- cannot be contacted -- does not make a service date CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 & 6. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment V. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information CUSTOMER VEHICLES: Parts will be shipped to your dealership according to the procedures established for "Low Volume Recalls or Owner Notification Programs". DO NOT order parts, except for dealer stock units (Refer to the attached All-Dealer letter). NOTE: When the customer calls the Coordination Center, the correct parts will be automatically sent to the Dealer. This will avoid having the customer return to the dealer if the vehicle fails the inspection. Parts not used may be returned for credit. (See "Excess Stock Return" below). STOCK VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4028 Correct all vehicles in stock before delivery. First, inspect all affected stock vehicles to determine parts requirements. Then, contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts. When calling this number, identify recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: 1999 EXPEDITION AND NAVIGATOR INSPECTION 1. Raise and support the vehicle. 2. Locate the build label on the front fuel supply line. The label is located just forward of the fuel filter. Refer to Figure 1. ^ If the build label is missing, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". 3. Using a shop towel, clean the label as necessary. 4. Check the month and day codes of the build label. See Figure 1. ^ If the fuel line build label has a build date code of August 21 ( H 21) or earlier, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4029 ^ If the fuel line has a build date code of August 22 ( H 22) or later, no service action is required. Return the vehicle to the customer. SERVICE PROCEDURE 1. Open the hood. 2. Remove the jack handle from the radiator support. WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 3. Relieve fuel system pressure as follows: ^ Remove the schrader valve cap and attach the EFI/CFI fuel pressure gauge. ^ Slowly open the manual valve on EFI/CFI fuel pressure gauge to relieve the fuel pressure. ^ Remove the fuel pressure gauge and reinstall the schrader valve. 4. Turn off the air suspension switch, located under the right side of the instrument panel, if equipped. 5. Install the memory saver, then disconnect the battery negative cable. 6. Disconnect both of the fuel lines from the fuel manifold. 7. Raise and support the vehicle. 8. Completely drain the fuel tank into appropriate container. 9. On 4 x 4 models, remove the transfer case skid plate, if equipped. 10. On 4 x 4 models, reposition the front driveshaft as follows: ^ Place an alignment mark on the driveshaft mounting flange and front axle flange. ^ Remove the driveshaft mounting flange retaining bolts. ^ Swing the driveshaft down and under the engine oil pan. This will allow access to the front fuel line clip. 11. On 4 x 4 models equipped with 4.6L engines, remove the CMS sensor Christmas tree fastener from the bracket at the rear of the transmission. 12. Disconnect the front fuel return line from the rear fuel return line. Connection is located near the fuel filter. 13. Disconnect the front fuel supply line from the fuel filter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4030 14. Unclip both of the front fuel lines from the back clip. See Figure 2. 15. Unclip both of the front fuel lines from the middle clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4031 16. Using the jack handle removed previously, unclip both of the front fuel lines from the front clip. See Figure 3. A 24 to 28-inch flat screwdriver will work instead of the jack handle. 17. Remove both of the front fuel lines from the vehicle. 18. Transfer the safety clips used on the fuel manifold connections, to the new front fuel lines. 19. On 4 x 4 models, remove the fuel filter from its mounting bracket and reposition it below the frame rail. 20. Disconnect the rear fuel supply line from the fuel filter. 21. On 4 x 4 models, install the fuel filter back into its mounting bracket. 22. Position an adjustable jack under the fuel tank. Raise the jack to support the fuel tank. 23. Remove the fuel tank straps. On 4 x 4 models, the skid plate and the fuel tank straps are riveted together. 24. Disconnect the fuel filler hose from the fuel tank. 25. Lower the fuel tank approximately 15 cm (6 in). On 4 x 4 models, lower the skid plate and fuel tank as an assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4032 26. Disconnect both of the rear fuel lines from the fuel pump. Refer to Figure 4. 27. Unclip both of the rear fuel lines from the back clip. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4033 28. Unclip both of the rear fuel lines from the front clip. See Figure 5. 29. Remove both of the rear fuel lines from the vehicle. 30. Position the new rear fuel supply line (blue convolute) on the vehicle. 31. Clip the rear fuel supply line in the front and back clips. 32. Position the new rear fuel return line (gray convolute) on the vehicle. 33. Clip the rear fuel return line in the front and back clips. 34. Connect the rear fuel lines to the fuel pump. Reattach the safety clips. 35. Raise the fuel tank to the installed position. 36. Install the fuel tank straps. Tighten the retaining bolts to 55 Nm (40 lb-ft). 37. Remove the adjustable jack. 38. Connect the fuel filler hose to the fuel tank. 39. Connect the rear fuel supply line to the fuel filter. Reattach the safety clip. 40. Position the front fuel supply line on the vehicle. 41. Clip the front fuel supply line in the front, middle and back clips. 42. Connect the front fuel supply line to the fuel filter. Reattach the safety clip. 43. Position the front fuel return line on the vehicle. 44. Clip the front fuel return line in the front, middle and back clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4034 45. Connect the front fuel return line to the rear fuel return line. Reattach the safety clip. 46. On 4 x 4 models, install the front driveshaft as follows: ^ Aligning the marks made previously, position the front driveshaft on the front axle flange. ^ Install the driveshaft mounting flange retaining bolts. Tighten the bolts to 103 Nm (76 lb-ft). 47. On 4 x 4 models, install the transfer case skid plate. Tighten the retaining bolts to 15 Nm (11 lb-ft). 48. Lower the vehicle. 49. Connect both of the fuel lines to the fuel manifold. Reattach the safety clip. 50. Install the jack handle on the radiator support. 51. Replace the fuel that was drained during step number 8. 52. Connect the battery negative cable, then remove the memory saver. 53. Turn the ignition key to the ON position to pressurize the fuel system. Check the fuel lines for leaks and repair as necessary. 54. Turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4035 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4036 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4037 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4038 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4039 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4040 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > NHTSA98V312000 > Dec > 98 > Recall 98V312000: Fuel line Assemblies, Leaks Fuel Supply Line: Recalls Recall 98V312000: Fuel line Assemblies, Leaks Vehicle Description: Sport utility vehicles. The fuel line assemblies may have been damaged by the supplier during manufacturing, allowing leakage. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will inspect these vehicles and, if necessary, replace the front and rear fuel line assemblies. Owner notification is expected to begin January 3, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks Technical Service Bulletin # 98S35 Date: 981201 Recall - Fuel Line Damage/Leaks SAFETY RECALL 98535 Certain 1999 Expedition and Navigator Vehicles Front and Rear Fuel Line Inspection ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment III ^ Technical Information ^ Attachment IV ^ New Part Procurement Process of Low Volume Recalls ^ Attachment V ^ Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4053 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4054 Attachment I - Administrative Information OASIS Owners will receive a notification letter that instructs them to call a toll-free number to arrange for parts to be shipped to the dealer of their choice. If it is necessary, use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1 00 per vehicle. You must contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number, identify Safety Recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER-OWNER CONTRACT You are requested to contact the owner and arrange for this service. Please note that our Coordination Center will advise owners that they will hear from you within the next two business days. (For more information, see attached copy of "Low Volume Announcement Letter" dated December 18, 1995. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment V to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4055 -- cannot be contacted -- does not make a service date CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 & 6. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment V. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information CUSTOMER VEHICLES: Parts will be shipped to your dealership according to the procedures established for "Low Volume Recalls or Owner Notification Programs". DO NOT order parts, except for dealer stock units (Refer to the attached All-Dealer letter). NOTE: When the customer calls the Coordination Center, the correct parts will be automatically sent to the Dealer. This will avoid having the customer return to the dealer if the vehicle fails the inspection. Parts not used may be returned for credit. (See "Excess Stock Return" below). STOCK VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4056 Correct all vehicles in stock before delivery. First, inspect all affected stock vehicles to determine parts requirements. Then, contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts. When calling this number, identify recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: 1999 EXPEDITION AND NAVIGATOR INSPECTION 1. Raise and support the vehicle. 2. Locate the build label on the front fuel supply line. The label is located just forward of the fuel filter. Refer to Figure 1. ^ If the build label is missing, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". 3. Using a shop towel, clean the label as necessary. 4. Check the month and day codes of the build label. See Figure 1. ^ If the fuel line build label has a build date code of August 21 ( H 21) or earlier, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4057 ^ If the fuel line has a build date code of August 22 ( H 22) or later, no service action is required. Return the vehicle to the customer. SERVICE PROCEDURE 1. Open the hood. 2. Remove the jack handle from the radiator support. WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 3. Relieve fuel system pressure as follows: ^ Remove the schrader valve cap and attach the EFI/CFI fuel pressure gauge. ^ Slowly open the manual valve on EFI/CFI fuel pressure gauge to relieve the fuel pressure. ^ Remove the fuel pressure gauge and reinstall the schrader valve. 4. Turn off the air suspension switch, located under the right side of the instrument panel, if equipped. 5. Install the memory saver, then disconnect the battery negative cable. 6. Disconnect both of the fuel lines from the fuel manifold. 7. Raise and support the vehicle. 8. Completely drain the fuel tank into appropriate container. 9. On 4 x 4 models, remove the transfer case skid plate, if equipped. 10. On 4 x 4 models, reposition the front driveshaft as follows: ^ Place an alignment mark on the driveshaft mounting flange and front axle flange. ^ Remove the driveshaft mounting flange retaining bolts. ^ Swing the driveshaft down and under the engine oil pan. This will allow access to the front fuel line clip. 11. On 4 x 4 models equipped with 4.6L engines, remove the CMS sensor Christmas tree fastener from the bracket at the rear of the transmission. 12. Disconnect the front fuel return line from the rear fuel return line. Connection is located near the fuel filter. 13. Disconnect the front fuel supply line from the fuel filter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4058 14. Unclip both of the front fuel lines from the back clip. See Figure 2. 15. Unclip both of the front fuel lines from the middle clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4059 16. Using the jack handle removed previously, unclip both of the front fuel lines from the front clip. See Figure 3. A 24 to 28-inch flat screwdriver will work instead of the jack handle. 17. Remove both of the front fuel lines from the vehicle. 18. Transfer the safety clips used on the fuel manifold connections, to the new front fuel lines. 19. On 4 x 4 models, remove the fuel filter from its mounting bracket and reposition it below the frame rail. 20. Disconnect the rear fuel supply line from the fuel filter. 21. On 4 x 4 models, install the fuel filter back into its mounting bracket. 22. Position an adjustable jack under the fuel tank. Raise the jack to support the fuel tank. 23. Remove the fuel tank straps. On 4 x 4 models, the skid plate and the fuel tank straps are riveted together. 24. Disconnect the fuel filler hose from the fuel tank. 25. Lower the fuel tank approximately 15 cm (6 in). On 4 x 4 models, lower the skid plate and fuel tank as an assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4060 26. Disconnect both of the rear fuel lines from the fuel pump. Refer to Figure 4. 27. Unclip both of the rear fuel lines from the back clip. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4061 28. Unclip both of the rear fuel lines from the front clip. See Figure 5. 29. Remove both of the rear fuel lines from the vehicle. 30. Position the new rear fuel supply line (blue convolute) on the vehicle. 31. Clip the rear fuel supply line in the front and back clips. 32. Position the new rear fuel return line (gray convolute) on the vehicle. 33. Clip the rear fuel return line in the front and back clips. 34. Connect the rear fuel lines to the fuel pump. Reattach the safety clips. 35. Raise the fuel tank to the installed position. 36. Install the fuel tank straps. Tighten the retaining bolts to 55 Nm (40 lb-ft). 37. Remove the adjustable jack. 38. Connect the fuel filler hose to the fuel tank. 39. Connect the rear fuel supply line to the fuel filter. Reattach the safety clip. 40. Position the front fuel supply line on the vehicle. 41. Clip the front fuel supply line in the front, middle and back clips. 42. Connect the front fuel supply line to the fuel filter. Reattach the safety clip. 43. Position the front fuel return line on the vehicle. 44. Clip the front fuel return line in the front, middle and back clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4062 45. Connect the front fuel return line to the rear fuel return line. Reattach the safety clip. 46. On 4 x 4 models, install the front driveshaft as follows: ^ Aligning the marks made previously, position the front driveshaft on the front axle flange. ^ Install the driveshaft mounting flange retaining bolts. Tighten the bolts to 103 Nm (76 lb-ft). 47. On 4 x 4 models, install the transfer case skid plate. Tighten the retaining bolts to 15 Nm (11 lb-ft). 48. Lower the vehicle. 49. Connect both of the fuel lines to the fuel manifold. Reattach the safety clip. 50. Install the jack handle on the radiator support. 51. Replace the fuel that was drained during step number 8. 52. Connect the battery negative cable, then remove the memory saver. 53. Turn the ignition key to the ON position to pressurize the fuel system. Check the fuel lines for leaks and repair as necessary. 54. Turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4063 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4064 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4065 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4066 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4067 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4068 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > NHTSA98V312000 > Dec > 98 > Recall 98V312000: Fuel line Assemblies, Leaks Fuel Supply Line: All Technical Service Bulletins Recall 98V312000: Fuel line Assemblies, Leaks Vehicle Description: Sport utility vehicles. The fuel line assemblies may have been damaged by the supplier during manufacturing, allowing leakage. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will inspect these vehicles and, if necessary, replace the front and rear fuel line assemblies. Owner notification is expected to begin January 3, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks Technical Service Bulletin # 98S35 Date: 981201 Recall - Fuel Line Damage/Leaks SAFETY RECALL 98535 Certain 1999 Expedition and Navigator Vehicles Front and Rear Fuel Line Inspection ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment III ^ Technical Information ^ Attachment IV ^ New Part Procurement Process of Low Volume Recalls ^ Attachment V ^ Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4078 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4079 Attachment I - Administrative Information OASIS Owners will receive a notification letter that instructs them to call a toll-free number to arrange for parts to be shipped to the dealer of their choice. If it is necessary, use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,1 00 per vehicle. You must contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number, identify Safety Recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER-OWNER CONTRACT You are requested to contact the owner and arrange for this service. Please note that our Coordination Center will advise owners that they will hear from you within the next two business days. (For more information, see attached copy of "Low Volume Announcement Letter" dated December 18, 1995. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment V to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4080 -- cannot be contacted -- does not make a service date CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 & 6. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment V. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information CUSTOMER VEHICLES: Parts will be shipped to your dealership according to the procedures established for "Low Volume Recalls or Owner Notification Programs". DO NOT order parts, except for dealer stock units (Refer to the attached All-Dealer letter). NOTE: When the customer calls the Coordination Center, the correct parts will be automatically sent to the Dealer. This will avoid having the customer return to the dealer if the vehicle fails the inspection. Parts not used may be returned for credit. (See "Excess Stock Return" below). STOCK VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4081 Correct all vehicles in stock before delivery. First, inspect all affected stock vehicles to determine parts requirements. Then, contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts. When calling this number, identify recall 98S35 and have the VIN of the dealer stock vehicle to be serviced. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: 1999 EXPEDITION AND NAVIGATOR INSPECTION 1. Raise and support the vehicle. 2. Locate the build label on the front fuel supply line. The label is located just forward of the fuel filter. Refer to Figure 1. ^ If the build label is missing, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". 3. Using a shop towel, clean the label as necessary. 4. Check the month and day codes of the build label. See Figure 1. ^ If the fuel line build label has a build date code of August 21 ( H 21) or earlier, replace the fuel lines. Lower the vehicle and proceed to the "Service Procedure". Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4082 ^ If the fuel line has a build date code of August 22 ( H 22) or later, no service action is required. Return the vehicle to the customer. SERVICE PROCEDURE 1. Open the hood. 2. Remove the jack handle from the radiator support. WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 3. Relieve fuel system pressure as follows: ^ Remove the schrader valve cap and attach the EFI/CFI fuel pressure gauge. ^ Slowly open the manual valve on EFI/CFI fuel pressure gauge to relieve the fuel pressure. ^ Remove the fuel pressure gauge and reinstall the schrader valve. 4. Turn off the air suspension switch, located under the right side of the instrument panel, if equipped. 5. Install the memory saver, then disconnect the battery negative cable. 6. Disconnect both of the fuel lines from the fuel manifold. 7. Raise and support the vehicle. 8. Completely drain the fuel tank into appropriate container. 9. On 4 x 4 models, remove the transfer case skid plate, if equipped. 10. On 4 x 4 models, reposition the front driveshaft as follows: ^ Place an alignment mark on the driveshaft mounting flange and front axle flange. ^ Remove the driveshaft mounting flange retaining bolts. ^ Swing the driveshaft down and under the engine oil pan. This will allow access to the front fuel line clip. 11. On 4 x 4 models equipped with 4.6L engines, remove the CMS sensor Christmas tree fastener from the bracket at the rear of the transmission. 12. Disconnect the front fuel return line from the rear fuel return line. Connection is located near the fuel filter. 13. Disconnect the front fuel supply line from the fuel filter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4083 14. Unclip both of the front fuel lines from the back clip. See Figure 2. 15. Unclip both of the front fuel lines from the middle clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4084 16. Using the jack handle removed previously, unclip both of the front fuel lines from the front clip. See Figure 3. A 24 to 28-inch flat screwdriver will work instead of the jack handle. 17. Remove both of the front fuel lines from the vehicle. 18. Transfer the safety clips used on the fuel manifold connections, to the new front fuel lines. 19. On 4 x 4 models, remove the fuel filter from its mounting bracket and reposition it below the frame rail. 20. Disconnect the rear fuel supply line from the fuel filter. 21. On 4 x 4 models, install the fuel filter back into its mounting bracket. 22. Position an adjustable jack under the fuel tank. Raise the jack to support the fuel tank. 23. Remove the fuel tank straps. On 4 x 4 models, the skid plate and the fuel tank straps are riveted together. 24. Disconnect the fuel filler hose from the fuel tank. 25. Lower the fuel tank approximately 15 cm (6 in). On 4 x 4 models, lower the skid plate and fuel tank as an assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4085 26. Disconnect both of the rear fuel lines from the fuel pump. Refer to Figure 4. 27. Unclip both of the rear fuel lines from the back clip. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4086 28. Unclip both of the rear fuel lines from the front clip. See Figure 5. 29. Remove both of the rear fuel lines from the vehicle. 30. Position the new rear fuel supply line (blue convolute) on the vehicle. 31. Clip the rear fuel supply line in the front and back clips. 32. Position the new rear fuel return line (gray convolute) on the vehicle. 33. Clip the rear fuel return line in the front and back clips. 34. Connect the rear fuel lines to the fuel pump. Reattach the safety clips. 35. Raise the fuel tank to the installed position. 36. Install the fuel tank straps. Tighten the retaining bolts to 55 Nm (40 lb-ft). 37. Remove the adjustable jack. 38. Connect the fuel filler hose to the fuel tank. 39. Connect the rear fuel supply line to the fuel filter. Reattach the safety clip. 40. Position the front fuel supply line on the vehicle. 41. Clip the front fuel supply line in the front, middle and back clips. 42. Connect the front fuel supply line to the fuel filter. Reattach the safety clip. 43. Position the front fuel return line on the vehicle. 44. Clip the front fuel return line in the front, middle and back clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4087 45. Connect the front fuel return line to the rear fuel return line. Reattach the safety clip. 46. On 4 x 4 models, install the front driveshaft as follows: ^ Aligning the marks made previously, position the front driveshaft on the front axle flange. ^ Install the driveshaft mounting flange retaining bolts. Tighten the bolts to 103 Nm (76 lb-ft). 47. On 4 x 4 models, install the transfer case skid plate. Tighten the retaining bolts to 15 Nm (11 lb-ft). 48. Lower the vehicle. 49. Connect both of the fuel lines to the fuel manifold. Reattach the safety clip. 50. Install the jack handle on the radiator support. 51. Replace the fuel that was drained during step number 8. 52. Connect the battery negative cable, then remove the memory saver. 53. Turn the ignition key to the ON position to pressurize the fuel system. Check the fuel lines for leaks and repair as necessary. 54. Turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4088 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4089 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4090 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4091 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4092 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S35 > Dec > 98 > Recall - Fuel Line Damage/Leaks > Page 4093 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4103 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4104 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4105 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4106 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4107 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4113 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4114 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4115 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4116 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4117 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4118 Fuel Filler Hose: Service and Repair REMOVAL WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the fuel tank filler cap. 2. Remove the screws. 3. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4119 4. Disconnect the fuel tank to filler pipe hose and remove the fuel tank filler pipe. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4128 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4129 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4130 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4131 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4132 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4138 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4139 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4140 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4141 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4142 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control (IAC) Valve Bolts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4146 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the IAC valve. 4. Remove the two bolts and the Idle Air Control (IAC) valve. 5. Remove and discard the Idle Air Control (IAC) gasket. INSTALLATION 1. To install, reverse the removal procedure. Install a new Idle Air Control (IAC) gasket. Tighten the two bolts in 2 stages. - Stage 1:10 Nm (89 lb-in) - Stage 2: Rotate 90 degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Service and Repair Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector. 4. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Remove the bolts. 2 Remove the (IFS) switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4153 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4156 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4161 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4162 Fuel Pump Relay: Description and Operation The Fuel Pump relay: - engages the fuel pump when energized by the powertrain control module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4163 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4164 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4168 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4171 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4181 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4182 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4188 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4189 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4190 Air Flow Meter/Sensor: Specifications Mass Air Flow Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4191 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4192 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Open the air cleaner. ^ Disconnect the mass air flow sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the Air Cleaner (ACL) from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the mass air flow sensor. Tampering may result in unit failure. NOTE: The mass air flow sensor module and body are calibrated and serviced as a unit. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4193 5. Remove the mass air flow sensor plate and Mass Air Flow (MAF) sensor from the outlet side of the air cleaner. 6. Disconnect the mass air flow sensor electrical connector from the extension harness. 7. Separate the mass air flow sensor plate from the mass air flow sensor ^ Remove the nuts from the mass air flow sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to properly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Service and Repair Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the RH cowl side trim panel. 3. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector. 4. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Remove the bolts. 2 Remove the (IFS) switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 02-19-3 > Sep > 02 > Emissions - High Idle Speeds/Throttle Sticking Throttle Body: Customer Interest Emissions - High Idle Speeds/Throttle Sticking Article No. 02-19-3 09/30/02 ^ DRIVEABILITY - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE ^ 4.6L - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE FORD: 1997-1999 F-250 LD 1997-2002 EXPEDITION, F-150 ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the PCV gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the PCV Service Kit 1L3Z-6A603-AA. Refer to the Instruction Sheet within the PCV Service Kit for Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021903A Replace PCV System with 1.5 Hrs. PCV Service Kit: 1997-2002 F-150, Expedition 1997-1999 F-250 LD DEALER CODING CONDITION BASIC PART NO. CODE 6C324 42 OASIS CODES: 401000, 402000, 404000, 499000, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 02-19-3 > Sep > 02 > Emissions - High Idle Speeds/Throttle Sticking Throttle Body: All Technical Service Bulletins Emissions - High Idle Speeds/Throttle Sticking Article No. 02-19-3 09/30/02 ^ DRIVEABILITY - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE ^ 4.6L - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE FORD: 1997-1999 F-250 LD 1997-2002 EXPEDITION, F-150 ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the PCV gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the PCV Service Kit 1L3Z-6A603-AA. Refer to the Instruction Sheet within the PCV Service Kit for Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021903A Replace PCV System with 1.5 Hrs. PCV Service Kit: 1997-2002 F-150, Expedition 1997-1999 F-250 LD DEALER CODING CONDITION BASIC PART NO. CODE 6C324 42 OASIS CODES: 401000, 402000, 404000, 499000, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4213 Throttle Body: Specifications Throttle Body Bolts 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4214 Throttle Body: Description and Operation The Throttle Body: ^ controls air supply to the upper intake manifold by positioning the throttle plate. ^ connects the accelerator cable and the speed control actuator cable (if equipped) to the throttle lever. ^ is not adjustable. ^ cannot be cleaned. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4215 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned. 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Remove the air cleaner outlet tube from the throttle body. 3. Disconnect the Throttle Position (TP) sensor electrical connector. 4. Disconnect the accelerator controls. 1 Disconnect the accelerator cable. 2 Disconnect the speed control cable. 3 Disconnect the return spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4216 5. Remove the throttle body. 1 Remove the bolts. 2 Remove the (A) throttle body and the (B) throttle body gasket. NOTE: Discard the Throttle Body gasket (TB gasket). INSTALLATION 1. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-12 > Sep > 99 > Accelerator Pedal Vibrates Throttle Cable/Linkage: Customer Interest Accelerator Pedal - Vibrates Article No. 99-18-12 09/06/99 ^ ENGINE - 4.6L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ ENGINE - 5.4L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ VIBRATION - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 AND WITH 4.6L OR 5.4L 2-VALVE ENGINE FORD: 1999 EXPEDITION LINCOLN: 1999 NAVIGATOR This TSB article is being republished in its entirety to provide engine applications. ISSUE A vibration may be felt in the accelerator pedal on some vehicles. This may be caused by the accelerator cable contacting the power steering reservoir. ACTION Replace accelerator cable with a revised cable and a new routing. The revised cable and routing should reduce the possibility of feeling vibration through the accelerator pedal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the accelerator cable following the procedure outlined in the 1999 Expedition/Navigator Workshop, Section 310-02. 2. Install revised Accelerator Cable (XL1Z-9A758-EA) following the removal procedure in reverse order. Route the cable outboard of the power Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest: > 99-18-12 > Sep > 99 > Accelerator Pedal Vibrates > Page 4225 steering reservoir and clip to the speed control cable (Figure 1). NOTE MAKE SURE CABLE IS NOT TOUCHING THE POWER STEERING RESERVOIR OR THE BRAKE BOOSTER VACUUM HOSE. PART NUMBER PART NAME XL1Z-9A758-EA Accelerator Cable OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991812A Install Revised Accelerator 0.4 Hr. Cable DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 OASIS CODES: 497000, 499000, 703000, 703200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-18-12 > Sep > 99 > Accelerator Pedal - Vibrates Throttle Cable/Linkage: All Technical Service Bulletins Accelerator Pedal - Vibrates Article No. 99-18-12 09/06/99 ^ ENGINE - 4.6L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ ENGINE - 5.4L 2-VALVE - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 ^ VIBRATION - VIBRATION FELT THROUGH ACCELERATOR PEDAL - VEHICLES BUILT THROUGH 1/10/1999 AND WITH 4.6L OR 5.4L 2-VALVE ENGINE FORD: 1999 EXPEDITION LINCOLN: 1999 NAVIGATOR This TSB article is being republished in its entirety to provide engine applications. ISSUE A vibration may be felt in the accelerator pedal on some vehicles. This may be caused by the accelerator cable contacting the power steering reservoir. ACTION Replace accelerator cable with a revised cable and a new routing. The revised cable and routing should reduce the possibility of feeling vibration through the accelerator pedal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the accelerator cable following the procedure outlined in the 1999 Expedition/Navigator Workshop, Section 310-02. 2. Install revised Accelerator Cable (XL1Z-9A758-EA) following the removal procedure in reverse order. Route the cable outboard of the power Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-18-12 > Sep > 99 > Accelerator Pedal - Vibrates > Page 4231 steering reservoir and clip to the speed control cable (Figure 1). NOTE MAKE SURE CABLE IS NOT TOUCHING THE POWER STEERING RESERVOIR OR THE BRAKE BOOSTER VACUUM HOSE. PART NUMBER PART NAME XL1Z-9A758-EA Accelerator Cable OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991812A Install Revised Accelerator 0.4 Hr. Cable DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 OASIS CODES: 497000, 499000, 703000, 703200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4237 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4238 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4244 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4245 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 4246 Throttle Cable/Linkage: Specifications Accelerator Cable Bracket Bolts 6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 4247 Throttle Cable/Linkage: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable, or interfere with the accelerator pedal and shaft. The vehicle is also available with an adjustable pedals option. This allows both the accelerator and brake pedals to be adjusted simultaneously forward or rearward. A rocker switch on the instrument panel provides adjustment on the pedals assembly when it is activated. On vehicles with the memory seat option, the pedals position can be controlled by the memory selection, as well as the rocker switch. The accelerator pedal and shaft can still be serviced separately on the adjustable pedals assembly. The components in the acceleration control system are not adjustable and must be replaced if damaged or worn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Flow of Diagnosis Throttle Cable/Linkage: Flow of Diagnosis 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft ^ Damaged linkage ^ Damaged accelerator cable ^ High engine idle speed ^ Damaged throttle body ^ Damaged or binding adjustable pedal assembly 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4250 Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft ^ Damaged linkage ^ Damaged accelerator cable ^ High engine idle speed ^ Damaged throttle body ^ Damaged or binding adjustable pedal assembly 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4251 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable Throttle Cable/Linkage: Service and Repair Accelerator Cable REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the left hand side accelerator control splash shield bolts. 3. Remove the right hand side splash shield bolt and remove the splash shield. 4. Remove the accelerator cable clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable > Page 4254 5. Squeeze the accelerator cable lock tabs on the inside of the passenger compartment and push the accelerator cable into the engine compartment. 6. Remove the fitting and the accelerator cable from the accelerator cable bracket. 7. Disconnect the accelerator cable from the throttle lever to remove the accelerator cable. 1 Rotate the throttle lever forward. 2 Slide the accelerator cable end from the throttle lever. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable > Page 4255 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable > Page 4256 Throttle Cable/Linkage: Service and Repair Accelerator Cable Bracket REMOVAL 1. Remove the left hand side accelerator control splash shield bolts. 2. Remove the right hand side accelerator control splash shield bolt and remove the splash shield. 3. Disconnect the speed control cable. 4. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever forward. ^ Slide the accelerator cable end from the throttle lever. 5. Depress the locking tabs and remove the accelerator cable from the accelerator cable bracket. 6. Remove the spring from the accelerator cable bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable > Page 4257 7. Remove the bolts and remove the accelerator cable bracket. NOTE: For clarity, the air intake duct is not shown in this illustration. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Service and Repair Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the bolts and the accelerator control splash shield. 3. Disconnect the electrical connector from the Throttle Position (TP) sensor. 4. Remove the screws and the Throttle Position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4265 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4266 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4274 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4278 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4279 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4280 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Description and Operation Ignition Cable: Description and Operation The spark plug wires carry high voltage pulses from the ignition coil to the spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Description and Operation > Page 4284 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Squeeze the locking tabs and disconnect the spark plug wire from the ignition coil. INSTALLATION 1. Apply Silicone Brake Caliper Grease Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. 2. To install. reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4289 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4290 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4291 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4292 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4293 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4294 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4295 Ignition Coil: Specifications Ignition Coil And Bracket Bolts, LH and RH 20-30 Nm Ignition Coil And Bracket Nut, LH 20-30 Nm Ignition Coil Bolts 5-7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views Ignition Coil: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 4298 Ignition Coil: Mechanical Diagrams The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 4299 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 4300 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4301 Ignition Coil: Description and Operation NOTE: The following image is a generic image and may not apply to your vehicle. PURPOSE The Electronic Ignition-High Data Rate System (EI) coils provide high voltage needed to jump the gap of the spark plugs and ignite the air/fuel mixture. CONSTRUCTION The coil pack contains multiple coils. Each coil within a coil pack contains a primary and secondary circuit. Primary Windings The windings in the primary circuit is wound on a silicon steel core bobbin. The primary circuit grounds use the same ground through the DIS module. Secondary Windings The winding in the secondary circuit is on a segmented bobbin. The secondary winding uses smaller gauge wire and more turns than the primary circuit. The secondary high tension towers are connected in pairs. OPERATION The ignition coil fires two spark plugs simultaneously, one on the compression stroke and one on the exhaust stroke. Effective Spark When a piston is on compression stroke, most of the ignition coil's available current jumps the gap of the spark plug firing from the center electrode to side electrode, because the resistance is low. Wasted Spark When the companion piston is on exhaust stroke, the spark is wasted. Very little coil energy is wasted. The companion plug fires from the side electrode to the center electrode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Ignition Coil: Service and Repair Ignition Coil REMOVAL NOTE: Procedure is for either RH or LH ignition coil RH ignition coil is shown. 1. Disconnect the ignition coil electrical connections. 1 Disconnect the ignition coil electrical connector. 2 Disconnect the radio capacitor electrical connector. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wires. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations. 3. Remove the ignition Coil. 1 Remove the bolts. 2 Remove the ignition coil. 4. Inspect the ignition Coil for damage. Install a new ignition coil as necessary. INSTALLATION NOTE: Procedure is for either LH or RH ignition coil: RH is shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 4304 1. Install the ignition coil. 1 Position the ignition coil. 2 Install the radio interference capacitor and the bolts. 2. Connect the ignition coil electrical connections. 1 Connect the ignition coil electrical connector. 2 Connect the radio capacitor electrical connector. 3. Squeeze the locking tabs and connect the spark plug wires. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 4305 Ignition Coil: Service and Repair Ignition Coil Bracket REMOVAL 1. Remove the ignition coils. 2. Remove the RH ignition coil bracket. 1 Remove the bolts. 2 Remove the bracket. 3. Remove the power steering hose bracket. 1 Remove the nuts. 2 Remove the bracket. 4. Remove the LH ignition coil bracket. 1 Disconnect the Camshaft Position (CMP) sensor electrical connector. 2 Remove the bolt. 3 Remove the bracket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 4306 1. Install the RH ignition coil bracket. 1 Position the RH ignition coil bracket. 2 Install the bolts. 2. Install the LH ignition coil bracket. 1 Position the LH ignition coil bracket. 2 Install the bolt. 3 Connect the CMP sensor electrical connector. 3. Install the power steering hose bracket. 1 Position the power steering hose bracket. 2 Install the nuts. 4. Install the ignition coils. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4310 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 4314 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4319 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4324 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector from the Camshaft Position (CMP) sensor. 3. Remove the bolt and the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt 12 Nm A/C Compressor Bolts 30 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4328 Crankshaft Position Sensor: Description and Operation The Crankshaft Position sensor (CKP) sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and Crankshaft Speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4329 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Remove the accessory drive belt. 2. Raise and support the vehicle. 3. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 4. Disconnect the A/C compressor. 1 Remove the bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the bolt and the Crankshaft Position (CKP) sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4330 1. To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4336 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4337 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4338 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4339 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4340 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4341 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4344 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4345 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 4346 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor (KS) 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4350 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the electrical connector from the Knock Sensor (KS). 3. Remove the Knock Sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4355 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm RH Original Spark Plug AWSF32PG If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. LH Original Spark Plug AWSF32P If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Replacement Spark Plug (Either Side) AWSF32PP If a Spark Plug is removed for Examinatiopn , it must be reinstalled in the same cylinder.If a new Spark Plug needs to be installed ,use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Spark Plugs 20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4356 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4357 Spark Plug: Description and Operation The spark plug. ^ change the high voltage pulse from the ignition coil into a spark which ignites the fuel and air mixture. ^ are different for the LH and RH side of the engine. ^ originally equipped on the vehicle have a Platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4358 Spark Plug: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and use a twisting, pulling motion to disconnect the spark plug wires from the spark plugs. CAUTION: Spark plug wires must be connected to the correct ignition coil terminal and spark plug. Mark the spark plug wire locations. 2. Remove the spark plugs. NOTE: Remove any foreign materials from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 4. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4359 5. Inspect for carbon fouling ^ Look for black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with a incorrect heat range, dirty air cleaner, too rich fuel mixture or excessive idling. ^ Clean the spark plug. 6. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 7. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 8. Inspect for overheating identified by a white or light gray-brown spots and white bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with a incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4360 9. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. 10. Adjust the spark plug gap as required. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4367 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4371 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80 - 100 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift motor bolts ................................................................................................................................... ........................................... 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4379 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4380 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4381 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4382 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4385 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4386 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4387 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4388 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications Shift Indicator: Specifications Transmission Column Shift Selector Tube Bracket Bolts ........................................................................................................................ 14 Nm (10 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications > Page 4394 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. ^ Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. ^ Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 4407 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 4413 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Page 4414 Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4425 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4426 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 4432 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 4433 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4434 Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 4435 Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay The Torque On Demand Relay is located behind center of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 4440 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4441 Four Wheel Drive Selector Relay: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4447 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4451 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4452 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4453 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4454 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 4461 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 4462 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 4469 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 4470 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4485 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4486 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4493 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4497 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80 - 100 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift motor bolts ................................................................................................................................... ........................................... 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4505 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4506 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4507 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4508 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4511 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4512 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4513 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 4514 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4520 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4524 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80 - 100 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4536 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4542 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 4543 Accumulator: Locations Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator Accumulator: Service and Repair 1-2 Accumulator Special Tools Removal 1. Use (A) Servo Piston Remover Replacer to compress the 1-2 accumulator cover and remove the (B) accumulator piston retaining ring. 2. NOTE: Note the location of the 1-2 accumulator springs for reference during assembly. 1 Remove the 1-2 accumulator cover. 2 Remove the lower 1-2 accumulator spring. 3 Remove the accumulator piston. 4 Remove the upper 1-2 accumulator spring. Installation 1. Install the 1-2 accumulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4546 1 Install the 1-2 accumulator upper spring. 2 Install the accumulator piston. 3 Install the 1-2 accumulator lower spring. 4 Install the cover and seal assembly. 2. Use (A) Servo Piston Remover Replacer to install the (B) accumulator piston retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4547 Accumulator: Service and Repair 2-3 Accumulator Removal 1. Remove the main control valve body. 2. Remove the 2-3 accumulator piston retainer. 3. Remove the accumulator piston and spring. Installation 1. Install the 2-3 accumulator assembly. 1 Install the accumulator piston. 2 Install the accumulator piston spring. 3 Install the accumulator spring retainer. 2. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4548 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 4552 REFERENCE: BAND/CLUTCH APPLICATION CHART 601 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo Band Apply Servo: Service and Repair Overderive Servo Special Tools Removal 1. Remove the main control valve body. 2. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on overdrive servo internal retaining ring. Use (A) Servo Piston Remover/Replacer to compress the servo spring then remove the (B) overdrive servo retaining ring. 3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring. Installation 1. Install the overdrive servo piston assembly. 1 Install the overdrive servo piston return spring. 2 Install the overdrive servo piston assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 4557 2. Use (at) Servo Piston Remover/Replacer Tool to install the (B) overdrive servo piston retaining ring. 3. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 4558 Band Apply Servo: Service and Repair Reverse Servo Assembly Special Tools Removal 1. Remove the main control valve body. 2. Use the Servo Piston Remover/Replacer to remove the reverse band servo retaining ring. 1 Compress the servo spring. 2 Remove the reverse band servo retaining ring. 3. NOTE: The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed. Remove the (A) reverse band servo cover, (B) reverse band servo piston and rod and (C} reverse band servo spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 4559 Installation NOTE: This is not an ordinary installation procedure and does not compensate for band wear. 1. NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. Install the reverse servo piston and return spring. ^ Do not install the piston cover. 2. Install the Servo Piston Selection Tool and tighten the band apply bolt. 3. Attach the Dial Indicator With Bracketry. ^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 4. Loosen the bolt until the piston stops against the tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 4560 5. Verify the amount of piston travel on the dial indicator is within specification. 6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two groove or (C) three groove, to bring the servo piston travel within specification. 7. Remove the dial indicator and servo selection tool. 8. Install the proper servo piston assembly spring and the reverse servo piston cover and seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 4561 9. Use the Servo Piston Remover/Replacer to install the reverse servo retaining ring. 1 Compress the servo spring. 2 Install the reverse band servo retaining ring. 10. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4562 Band Apply Servo: Tools and Equipment Special Tools Special Tools SPECIAL TOOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T Clutch: Specifications Clutch, A/T 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4567 REFERENCE: BAND/CLUTCH APPLICATION CHART 601 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4568 Clutch: Specifications Clearance 0.062 - 0.085 in Snap Ring Thickness 0.050 - 0.054 inch 0.064 - 0.068 inch 0.078 - 0.082 inch 0.092 - 0.096 inch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4569 Clutch: Specifications Forward Clutch GENERAL SPECIFICATIONS Clearance ............................................................................................................................................ ..................... 1.27 - 2.38 mm (0.050 - 0.094 inch) Snap Ring Thickness ........................................... ................................................................................................................................... 1.524 - 1.625 mm (0.060 - 0.064 inch) ...................................................................................................................... ........................................................ 1.880 - 1.981 mm (0.074 - 0.078 inch) ....................................... ....................................................................................................................................... 2.235 - 2.337 mm (0.088 - 0.092 inch) ...................................................................................................................... ........................................................ 2.591 - 2.692 mm (0.102 - 0.106 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4570 Clutch: Specifications Clearance 1.677 - 1.643 in Snap Ring Thickness 0.067 - 0.071 inch 0.077 - 0.0081 inch 0.087 - 0.091 inch 0.097 - 0.101 inch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch, A/T > Page 4571 Clutch: Specifications Clearance 0.072 - 0.112 in Snap Ring Thickness 0.060 - 0.064 inch 0.074 - 0.078 inch 0.088 - 0.092 inch 0.102 - 0.106 inch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications Automatic Transmission Dipstick - Dipstick Tube: Specifications Transmission Fluid Filler Tube Bolt 13.5 - 16.5 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications > Page 4575 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Removal 1. Remove the transmission fluid filler tube bolt from the side of the RH cylinder head. 2. Remove the fluid filler tube. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension Housing Bolts 18 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications > Page 4579 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4584 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4585 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Capacity Including Cooler A/T Fluid .............................................................................................................................................. ......................................................... 13.2L (13.9 Qt) Total Fill Capacity A/T Fluid 4R70W ................................................................................................................................................. ......................................................... 13.1L (13.9 Qt) 4R100 .................................................................................................................................................. ............................................................. 15L (15.9 Qt) NOTE: Approximate - make final inspection with dipstick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4588 Fluid - A/T: Fluid Type Specifications NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Automatic (4R70W) ............................................................................................................................. ..................................................... MERCON V ATF Automatic (4R100) ............................................................................................................................................................. MERCON or MERCON V ATF Automatic (E40D) ............................................................................................................................................................. MERCON or MERCON V ATF NOTE: Automatic transmissions requiring MERCON V should only be serviced with MERCON V, or fluid from a container that is specified as a dual usage fluid: MERCON/MERCON V. NOTE: Automatic transmissions requiring MERCON can not be serviced with MERCON, MERCON V, or dual usage fluids labeled MERCON/MERCON V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4589 Fluid - A/T: Diagrams PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4590 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4591 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4592 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4593 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4594 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4595 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4596 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4597 LINE/SRV PRESSURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4598 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4599 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4600 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4601 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4602 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4603 4TH GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4604 MANUAL 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4605 MANUAL 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4606 MANUAL 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4607 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4608 Fluid - A/T: Testing and Inspection FLUID LEVEL CHECK CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the do not drive mark or internal failure could result. NOTE: If vehicle has been operated for an extended period of time at highway speeds, city traffic, hot weather, or pulling a trailer, the fluid needs to cool down to obtain an accurate reading. NOTE: The fluid level reading on the indicator will differ from operating and ambient temperatures. The correct reading should be within the normal operating temperature range. Under normal circumstances, the fluid level should be checked during normal maintenance. If the transmission starts to slip, shift slowly, or has signs of fluid leaking, the fluid level should be checked. 1. With the transmission in (P) PARK, the engine at idle, foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the range selector lever in the PARK position. 2. Wipe the fluid level indicator cap and remove the indicator. 3. Wipe the indicator with a clean cloth. 4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating temperature range. HIGH FLUID LEVEL A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated, refer to Transmission Fluid Drain and Refill. LOW FLUID LEVEL A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. ADDING FLUID CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid. FLUID CONDITION CHECK 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor. 3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter, coolers, and cooler lines. Perform diagnostic checks and adjustments; refer to the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4609 Diagnosis by Symptom Index. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4610 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid. ^ Normal Maintenance ^ No recommended changes ^ Special Operating Conditions, Change fluid at 48,000 km (30,000 miles) 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level. Removal 1. Disconnect the battery ground cable. 2. Raise and support vehicle on hoist. 3. Place a drain pan under the transmission fluid pan 4. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. ^ Replace transmission fluid pan gasket as necessary. 6. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4611 7. Remove the torque converter drain plug and drain the torque converter. ^ Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A) transmission fluid pan, (B)transmission fluid pan gasket and (C) magnet. 9. Flush the fluid cooler and fluid cooler lines. 10. Flush the torque converter. Installation 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4612 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan 5. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 6. Install bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4613 7. Lower the vehicle. 8. Connect the battery ground cable. 9. NOTE: When filling a dry transmission and torque converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. ^ Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent fluid meeting FORD specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Cooler Tube Nut to Case Fitting 9.8 - 16 ft.lb Fluid Cooler Line Case Fittings 21 - 25 ft.lb Transmission Fluid Cooler Line Fitting 12 - 17.5 ft.lb Auxiliary Transmission Fluid Cooler Bolts 44 - 62 ft.lb Transmission Fluid Cooler Tubes (5/16 inch) 21 - 25 ft.lb Transmission Fluid Cooler Tubes (3/8 inch) 18 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4617 Fluid Line/Hose: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 3. Remove the lower air deflector. 1 Remove the bolts. 2 Remove the lower air dam. 4. NOTE: Note the differences, in the tube routing between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles without an auxiliary fluid cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4618 For 4R70W Transmission-equipped vehicles, remove the transmission fluid cooler tube. 1 Remove the clips. 2 Disconnect the tube fittings. 3 Remove the transmissions fluid cooler tube 5. NOTE: Note the differences in the tube routing between (A) vehicles with a Transmission auxiliary fluid cooler and (B) vehicles without an auxiliary fluid cooler. For E4OD Transmission-equipped vehicles, remove the transmission fluid cooler tube. 1 Remove the clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube Installation 1. NOTE: Note the differences in the tube routing between the vehicles with a transmission auxiliary fluid cooler and the vehicles without an auxiliary fluid cooler. Install the transmission fluid cooler tube 1 Position the Transmission fluid cooler tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4619 2 Connect the tube fittings. 3 Install the clips. 2. On E40D Transmission-equipped vehicles, connect the transmission fluid cooler tubes to the cooler bypass valve. 3. Install the lower air deflector. 1 Position the lower air dam. 2 Install bolts. 4. Install the front skid plate. ^ Install the bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill the transmission fluid to the proper level and inspect for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission Fluid Pan Bolts 9 - 11 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4623 Fluid Pan: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Place a drain pan under the transmission fluid pan 4. Drain the transmission fluid. ^ Loosen the transmission fluid pan bolts and allow the fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 7. Remove torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4624 8. Rove the torque converter drain plug and drain the torque converter. ^ Rotate the crankshaft to access the drain plug. 9. Clean and inspect: the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 10. Flush the fluid cooler and fluid cooler lines. 11. Flush the torque converter. Installation 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4625 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 6. Install bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4626 7. Lower the vehicle. 8. Connect the battery ground cable. 9. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts ). Fill transmission to proper fluid level. ^ Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Front Pump Bolts 15 - 19 ft.lb Front Pump Support Bolts 15 - 19 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications Shift Indicator: Specifications Transmission Column Shift Selector Tube Bracket Bolts ........................................................................................................................ 14 Nm (10 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications > Page 4634 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. ^ Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. ^ Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: Customer Interest A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4646 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4647 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4648 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4654 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4655 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4656 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4660 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4665 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4669 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4670 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4671 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4672 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4673 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 4679 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 4680 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4685 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications TORQUE SPECIFICATIONS Selector Lever Arm And Support Bolts ............................................................................................................................... 12.7-17.2 Nm (10-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 4689 Shifter A/T: Service and Repair 1. Remove the ignition switch lock cylinder. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. 1 Disconnect the electrical connector. 2 Remove and discard the gearshift lever pin. 3 Remove the gearshift lever. Installation 1. NOTE: The gearshift lever pin must be replaced whenever removed. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications Manual Lever Shaft Inner Nut 19 - 27 ft.lb Manual Lever Shaft Outer Nut 22 - 26 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4694 Selector Shaft: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. On 4x4 vehicles, remove the front driveshaft. 1 Remove the eight front driveshaft bolts (four each end). 2 Remove the front driveshaft. 4. Drain the transmission fluid and remove the fluid pan and filter. 5. Disconnect digital TR sensor electrical connector. 6. Disconnect the transmission shift linkage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4695 7. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the outer manual control lever shaft nut. 2 Remove the manual control lever. 8. Remove the digital transmission range TR sensor. 1 Remove the two bolts. 2 Remove the digital TR sensor. 9. Remove the manual control valve detent lever spring 1 Remove the bolt. 2 Remove the manual control valve detent lever spring 10. NOTE: Use a shop cloth to protect the transmission case surface. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4696 Remove the manual lever shaft retaining pin. 11. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. 12. Remove the parking lever actuating rod. 1 Remove the manual valve detent lever. 2 Remove the parking lever actuating rod. 13. CAUTION: Use care not to damage the manual control lever shaft bore. New seal may leak. Remove the manual control lever shaft seal. Installation 1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4697 2. Install the parking lever actuating rod. 1 Install the parking lever actuating rod. 2 Install the manual valve detent lever. 3. Install the manual control lever shaft. 1 Install the manual control lever shaft. 2 Install the inner manual control lever shaft nut. 3 In stall the manual lever shaft retaining pin. 4. Install the manual valve detent lever spring. 1 Position the manual valve detent lever spring. 2 Install the manual valve detent lever spring bolt. 5. Install the digital TR sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4698 1 Install the digital TR sensor. 2 Loosely install the bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use Digital Transmission Range (TR) Sensor Alignment Tool to align the digital TR sensor slots. 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With manual lever in overdrive, connect the shift control cable. 10. Install digital TR sensor electrical connector. 11. Install the filter and transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4699 12. On 4X4 vehicles, install the front driveshaft. 1 Position the front driveshaft. 2 Install the eight front driveshaft bolts (four each end). 13. Lower the vehicle. 14. Connect the battery ground cable. 15. Fill the transmission with fluid and inspect for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 4700 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > 4R70W Shift Cable: Specifications Shift Cable Bracket Bolts 16 - 21 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > 4R70W > Page 4705 Shift Cable: Specifications Shift Cable Bracket Bolts 22 - 29 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W Shift Cable: Adjustments 4R70W 1. Place the gearshift lever in the (D) position. ^ Place an eight pound weight on the gearshift lever. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the R.H. kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. 1 Place the manual control lever in the first gear position. 2 Move the manual control lever two detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W > Page 4708 7. Lock the transmission shift cable lock tab. 8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Remove the eight pound weight. 10. Carefully move the manual control lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital Transmission Range (TR) or Transmission Range (TR) sensor adjustment in NEUTRAL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W > Page 4709 Shift Cable: Adjustments 4R100 1. Place the gearshift lever in the 16) position. ^ Place an eight pound weight on the gearshift lever. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the R.H. kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. 1 Place the manual control lever in the first gear position. 2 Close the manual control lever two detents to the (D) position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W > Page 4710 6. Connect the transmission shift cable to the manual control lever. 7. Lock the transmission shift cable lock tab. 8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 9. Remove the eight pound weight. 10. Carefully move the manual control lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital Transmission Range (TR) or Transmission Range (TR) sensor adjustment in NEUTRAL. ^ Readjust if necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4711 Shift Cable: Service and Repair Removal 1. Disconnect the transmission shift cable from the steering column. 1 Disconnect the transmission shift cable from the transmission selector lever arm and support 2 Disconnect the transmission shift cable from the steering column instrument panel bracket 2. Disconnect the cable push pin. 3. Push the rubber grommet and transmission shift cable through the bulkhead. 4. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 5. Remove the transmission shift cable from the automatic transmission. 1 Disconnect the transmission shift cable from the manual control lever. 2 Depress the lock tabs to release the transmission shift cable and disconnect the transmission shift cable from the transmission shift cable bracket. 6. Remove the shift cable bracket from the transmission (4.6L). 1 Remove the bolts. 2 Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4712 7. Remove the shift cable bracket from the transmission (5.4L). 1 Remove the bolts. 2 Remove the shift cable bracket. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. ^ Adjust the shift cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 4721 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 4727 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4728 Torque Converter: Specifications Stall Speed K Factor 165 Min 2200 Max 2500 End Play New or Rebuilt 0.014 - 0.041 in Used 0.014 - 0.074 in Torque Converter Drain Plug 21 - 23 ft. lbs. Torque Converter Nuts 20 - 34 ft. lbs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4729 Torque Converter: Description and Operation The torque converter transmits and multiplies torque. The torque converter is a four-element device: ^ impeller assembly ^ turbine assembly ^ reactor assembly ^ clutch and damper assembly The standard torque converter components operate as follows: ^ Rotation of the converter housing and impeller set the fluid in motion. ^ The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. ^ The reactor redirects fluid going back into the impeller, allowing for torque multiplication. ^ The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis Torque Converter: Testing and Inspection Torque Converter Diagnosis Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Condition-Perform the Torque Converter Clutch Operation Test. 4. Perform Diagnostic Procedures. ^ Run on-board diagnostics. Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. ^ Perform Line Pressure Test. ^ Perform Stall Speed Test. ^ Perform Diagnostic Routines. Use the Diagnosis by Symptom index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before charging the torque converter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4732 Torque Converter: Testing and Inspection Torque Converter Operation Test 1 Of 2 2 Of 2 This test verifies that the torque converter clutch control system and the torque converter are operating properly. 1. Perform Quick Test. Check for DTCs. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in the Diagnosis by Symptom Chart. 6. If the vehicle stalls in (D) or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to Torque Converter Operation Concerns in the Diagnosis by Index. Repair as required. If the vehicle does not stall in (D), refer to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4733 Diagnosis by Symptom. 7. If the vehicle exhibits a vibration during the road test complete the Road Test Evaluation Form. This forth will aid the technician in determining the source of the vibration. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter clutch shoulder. a. spark plugs - check for cracks, high resistance or broken insulators b. plug wires c. fuel injector filter may be plugged d. fuel contamination - poor engine performance e. EGR valve - valve may let in too much exhaust gas and cause engine to run lean f. vacuum leak - engine will not get proper air/fuel mixture g. MAP/MAF sensor - improper air/fuel mixture h. HEGO sensor - too rich lean air/fuel mixture i. fuel pressure - may be too low j. engine mounts -loose/damaged mounts can cause vibration concerns k. axle joints - check for vibration Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80 - 100 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 4745 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 4746 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 4747 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 4753 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 4754 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 4759 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 4760 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 4761 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 4767 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 4768 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4769 Transmission Cooler: Specifications Front Skid Plate 10.5 - 12 ft.lb Lower Air Deflector Bolts 10.5 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > With Auxiliary Cooler Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > With Auxiliary Cooler > Page 4772 Transmission Cooler: Locations Without Auxiliary Cooler 4R70W TRANSMISSION WITHOUT AUXILIARY COOLER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > Page 4773 Transmission Cooler: Description and Operation All vehicles with automatic transmissions are equipped with an integral transmission fluid cooler. The integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be repaired separately. Some vehicles are equipped with an optional auxiliary transmission fluid cooler that is mounted in front of the radiator. In operation, transmission fluid travels from the transmission to the auxiliary transmission fluid cooler, if equipped, to the integral transmission fluid cooler then back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview When fluid leakage is found at the any of the transmission fluid cooling components, the component must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4776 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Cooler: Service and Repair Auxiliary Removal 1. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 2. Place a drain pan under the auxiliary transmission fluid cooler. 3. Remove the auxiliary transmission fluid cooler 1 Disconnect the auxiliary transmission fluid cooler tubes. 2 Remove the bolts. 3 Remove the auxiliary transmission fluid cooler Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 4779 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 4780 Transmission Cooler: Service and Repair Backflushing and Cleaning 1. Conduct backflushing with a Torque Converter/Oil Cooler Cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 2. To aid in attaching the cleaner to the transmission steel cooler lines connect two additional rubber hose, to the transmission end of the steel transmission cooler lines. 1 Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). 2 Connect a tank return hose to the steel transmission cooler pressure line (shorter line). 3 Place the outlet end of this hose in the solvent tank reservoir. 4 Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on an d off will help dislodge contaminants in cooler system). 4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line. 5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed. 6. Remove the rubber return hose from the remaining steel cooler line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Page 4781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4788 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4793 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4794 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4795 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4796 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4797 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4798 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4799 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4800 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4801 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4802 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4803 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4804 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4805 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4806 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4807 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4808 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4809 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4810 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4811 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4812 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4813 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4814 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4824 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4825 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4826 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4827 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4828 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4829 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4830 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4831 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4832 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4833 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4834 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4835 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4838 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4839 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4840 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4841 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4842 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4843 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4844 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4847 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4848 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4849 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4850 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4851 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4852 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4853 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4855 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4856 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4857 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4858 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4859 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4860 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4861 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4862 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4863 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4864 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4865 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4866 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4867 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4868 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4869 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4870 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4871 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4872 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4873 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4874 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4875 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4876 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4877 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4878 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4879 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4880 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4881 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4882 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4883 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4884 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4885 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4886 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4887 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 4888 Transmission Mount: Specifications Rear Transmission Crossmember Bolts 64 - 81 ft.lb Transmission Mount Nuts 73 - 97 ft.lb Transmission Mount Bolts 64 - 81 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 4889 Transmission Mount: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. Remove the rear driveshaft. 1 Remove the four bolts. 2 Remove the driveshaft. 4. Use High-Lift Jack to support the transmission. 5. Remove the nuts. 6. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 4890 7. Remove the transmission crossmember. 1 Remove the bolts. 2 Remove the transmission crossmember. 8. Remove the rear support insulator. Installation 1. Install the rear support insulator. 2. Install the transmission crossmember. 1 Position the transmission crossmember. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 4891 3. Install the transmission crossmember bolts. 4. Remove the High-Lift Jack. 1 Install the nuts. 5. Install the drive shaft. 6. Lower the vehicle. 7. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4895 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4896 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4897 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4898 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4899 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 4905 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 4906 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Main Control Valve Body Bolts 80 - 98 in.lb Main Control Valve Body Cover Plate Bolts 80 - 98 in.lb Main Control Valve Body Separator Plate Bolts 80 - 98 in.lb Valve Body Reinforcement Plates 80 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation 1. Disconnect battery ground cable. 2. Raise and support the vehicle. 3. Drain transmission fluid and remove the transmission fluid pan and filter. 4. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 5. Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1 Remove the bolts. 2 Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4912 6. Remove the manual valve detent spring 1 Remove the bolt. 2 Remove the manual valve detent spring. 7. Remove the 23 valve body to case bolts. 8. Remove the main control valve body and discard the pump outlet screen. Installation 1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4913 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 4. Install the manual valve detent spring. 1 Position the manual valve detent spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4914 2 Install the bolt. 5. Tighten the main control valve body bolts in the sequence shown. 6. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1 Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 2 Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4915 7. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 8. CAUTION: If installing a new filter, and the grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore. NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. Replace fluid filter and seal as required. 9. Position the (B) pan magnet into the (A) transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4916 10. NOTE: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 11. Install the bolts. 12. Lower the vehicle. 13. Connect the battery ground cable. 14. Fill the transmission with fluid and check for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4917 Valve Body: Service and Repair Disassembly and Assembly Main Control Valve Body - 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4918 Main Control Valve Body - 2 of 2 1. Remove the Torque Converter Clutch Solenoid (TCC solenoid) and the shift solenoid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4919 1 Remove the bolt. 2 Remove the shift solenoid. 3 Remove the torque converter clutch solenoid. 2. Remove the three reinforcement plates. 1 Remove the bolts. 2 Remove the plates. 3. Remove the separator plate and discard the gaskets. 4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the eight coasting booster valve shuttle balls. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4920 5. Remove the converter drain back valve and solenoid pressure supply screen. 6. Remove the main control valve body cover plate. 1 Remove the thirteen bolts. 2 Remove the valve body cover plate and gasket. Assembly 1. NOTE: Before beginning assembly, perform/inspect the following: When building tip subassemblies and assembling the transmission, ALWAYS use new gaskets and seals All fasteners must be tightened to the torque specification indicated. In addition to appearing in the section, the necessary torques can be found in the General Specifications Chart. When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces. Install the valve body cover plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4921 1 Position the valve body cover plate gasket and cover plate. 2 Install the two guide pin bolts. 3 Install the bolts. 2. Tighten the bolts, in the sequence shown. 3. Install the eight coasting booster valve shuttle balls. 4. Install the converter drain back valve and solenoid pressure supply screen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4922 5. Install the separator plate and gaskets. 6. Install the three reinforcement plates. 1 Position the plates. 2 Install the bolts. 7. NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. Install the shift solenoid. 1 Position the shift solenoid. 2 Position the TCC solenoid. 3 Install the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored Wiring Harness: Customer Interest A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Article No. 99-19-7 09/20/99 ^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1999 TOWN CAR MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to include additional vehicles and to correct the Service Procedure. ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect. ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop Manual. If root cause is not determined, continue with this TSB. 2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4931 3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect (-7G276-) per the appropriate model Workshop Manual, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4932 4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect (F8AZ-7G276-AA). 5. Reassemble. PART NUMBER F8AZ-7G276-AA Bulkhead Interconnect F8AZ-7G276-BA Solenoid Interconnect OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4933 OPERATION DESCRIPTION TIME 991907A Perform Inspection And 1.3 Hrs. Replace Bulkhead Interconnect DEALER CODING CONDITION BASIC PART NO. CODE 7G276 42 OASIS CODES: 206000, 501000, 502000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Wiring Harness: All Technical Service Bulletins A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Article No. 99-19-7 09/20/99 ^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1999 TOWN CAR MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to include additional vehicles and to correct the Service Procedure. ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect. ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop Manual. If root cause is not determined, continue with this TSB. 2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4939 3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect (-7G276-) per the appropriate model Workshop Manual, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4940 4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect (F8AZ-7G276-AA). 5. Reassemble. PART NUMBER F8AZ-7G276-AA Bulkhead Interconnect F8AZ-7G276-BA Solenoid Interconnect OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 4941 OPERATION DESCRIPTION TIME 991907A Perform Inspection And 1.3 Hrs. Replace Bulkhead Interconnect DEALER CODING CONDITION BASIC PART NO. CODE 7G276 42 OASIS CODES: 206000, 501000, 502000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The CPP switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > Customer Interest for Carrier Side Gears: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Carrier Side Gears: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Side Gears: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Carrier Side Gears: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Drive Axle Differential Case: Specifications Front Drive Axle GENERAL SPECIFICATIONS Housing spreader adapter thread engagement ..................................................................................................................................... 12.7 mm (0.5 inch) Differential case maximum runout ............................................................................................................................................... 0.076 mm (0.003 inch) TORQUE SPECIFICATIONS Differential Housing Cover Bolts ....................................................................................................................................................... 32 Nm (24 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Drive Axle > Page 4965 Differential Case: Specifications 8.8 Inch Ring Gear GENERAL SPECIFICATIONS Differential case maximum runout ............................................................................................................................................... 0.076 mm (0.003 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Drive Axle > Page 4966 Differential Case: Specifications 9.75 Inch Ring Gear GENERAL SPECIFICATIONS Differential Case Maximum Runout ............................................................................................................................................................. 0.076 (0.003) TORQUE SPECIFICATIONS Rear Axle Housing Vent .............................................................................................................................................................. 11-24 Nm (8-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4967 Differential Case: Testing and Inspection Special Tools 1. Remove the front drive axle assembly. 2. Remove the differential housing cover. 1 Remove the drain plug. 2 Drain the lubricant. 3 Remove the bolts. 4 Remove the differential housing cover. 3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier. Install the special tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4968 4. Install the special tool. 5. Rotate the differential and check the ring gear backface runout. ^ If the ring gear backface runout exceeds the specification, the cause may be a warped ring gear, differential case damage, or loss of differential bearing preload. To determine the cause, proceed as follows: 6. Remove the pinion gear. 7. Remove the Differential Carrier Spreader. 8. Install the differential assembly with the differential bearing cups in the carrier housing. 9. Install the differential bearing shim on the left side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4969 10. Install the LH differential bearing cap. 1 Position the bearing cap. 2 Install the bolts finger-tight. 11. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim can be assembled with a slight drag feel. 12. Install the RH bearing cap, and tighten the four bolts. 13. Rotate the assembly to make sure it turns freely. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4970 14. Install the special tool. 15. Rotate the differential and check the ring gear backface runout. ^ If the runout is within the specifications, insufficient bearing preload caused the original out-of-specification runout. If the runout still exceeds the specification, proceed as follows: 16. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. 17. Remove the differential case from the housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4971 18. Remove the ring gear. ^ Remove the ten bolts. ^ Use a drift punch to separate the ring gear from the differential case. 19. Install the differential case in the housing. 1 Position the differential case. 2 Install the bearing caps. 3 Install the bolts. 4 Rotate the differential case to make sure the bearings have seated correctly. 20. Install the special tool. 21. Rotate the differential case and check the differential case runout. ^ If the runout does not exceed the specification, install a new ring gear and pinion. If runout exceeds the specification, the ring gear is true and the condition is due to differential case/differential bearing damage. Inspect the differential bearings and the differential case. Always install new differential bearings when installing a new differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4972 22. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. 23. Remove the differential case from the housing. 24. If necessary, using the special tools, remove the differential bearings. 25. CAUTION: Press against the differential bearing inner cone only. Install the new differential bearings. 1 Position the appropriate differential bearing (RH or LH). 2 Using a suitable press and the special tool, install the differential bearing. 3 Repeat the procedure for the other differential bearing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4973 26. Install the differential case in the housing. 1 Position the differential case. 2 Install the bearing caps. 3 Install the bearing cap bolts. 4 Rotate the differential case to make sure the bearings have seated correctly. 27. Install the special tool. 28. Recheck the runout with the new differential bearings. If the runout does not exceed the specification, use the new differential bearings for assembly. If the runout is still excessive, install a new differential case. 29. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4974 30. Remove the differential case from the housing. 1 Remove the bearing caps. 2 Remove the differential case. 31. Install the pinion gear, the ring gear and the differential assembly. 32. Install the front drive axle assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front Differential Case: Service and Repair Front Disassembly 1. Remove the differential assembly from the differential carrier housing. 2. Remove the ring gear. ^ Remove the ten bolts. ^ Use a drift punch to separate the ring gear from the differential case. 3. Remove the differential pinion shaft bolt. 4. Remove the differential pinion shaft. 5. Remove the differential pinion thrust washers and the differential pinion gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4977 1 Rotate the differential pinion gears to the differential case window, and remove them. 2 Separate the thrust washers from the gears. 6. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gears. 4. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble them. ^ Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4978 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. 8. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G3 15-A5 and ESE-M4G204-A2 prior to installation. Install a new differential pinion shaft bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4979 9. CAUTION: Do not press on the bearing. Install the ring gear. 1 Position three bolts to align the holes in the ring gear and the differential case. 2 Using a suitable press, install the ring gear. 10. Install the remaining bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4980 Differential Case: Service and Repair 8.8 Inch Ring Gear Removal and Installation Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. 3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4981 4. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position the special tool and inspect ring gear backlash and ring gear backface runout. 5. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Mark the bearing cap position before removal. Loosen the differential case. 1 Remove the four bearing cap bolts. 2 Remove the two bearing caps. 6. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the rear axle housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4982 7. Remove the 10 ring gear bolts. 8. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 9. Install the differential case. ^ Position the differential case assembly, including the bearing clips and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. 10. Position the special tool. 1 Rotate the differential case to ensure the differential bearings are correctly seated. 2 Position the special tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4983 11. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. 12. Remove the differential case from the rear axle housing and remove the differential bearings using the special tools. 13. Using the special tool, install the new differential bearings on the differential case. 14. Install the differential case. Position the differential case assembly, including the bearing caps, bolts and shims, in the rear axle housing. Tighten bearing caps to specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4984 15. Measure the differential case runout without the ring gear. ^ Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced. Installation 1. CAUTION: Make sure the notches on the case flange and the anti-lock speed sensor ring are aligned. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case. 2. Install the ring gear bolts. ^ Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2C349-A1 to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4985 4. Install a 6.73 mm (0.26 inch) shim on the left side. 5. CAUTION: Mark the position off the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated. Install the left bearing cap and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4986 8. Rotate the differential case to make sure it rotates freely. 9. Using the special tool, measure the ring gear backlash. ^ If the backlash is within specification, go to Step 14. The specification shown is the full allowable range. ^ If a zero backlash condition occurs, go to Step 10. ^ If the backlash is not within specification, go to Step 11. 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Check the backlash. Repeat Step 9. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4987 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. ^ If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential several times to make sure the differential bearings are correctly seated. 13. Using the special tool, recheck the backlash. ^ If the backlash is within specification, go to Step 14. If the backlash is not within specification, repeat Step 9. ^ The specification shown is the full allowable range. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4988 14. Remove the bearing caps anal bolts. ^ To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. ^ Using the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely. 15. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Install the bearing caps and bearing cap bolts. 16. Using the special tool, recheck the backlash. 17. Install the shafts. Conventional Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4989 Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4990 4. NOTE: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring, if required. 5. If required, using the special tools, remove the differential bearings. 6. Remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4991 8. Rotate and remove the differential pinion gears and differential pinion thrust washers. 9. Remove the differential side gears and the differential pinion thrust washers. Assembly 1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M7C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. ^ Position the differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4992 3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2,C192-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion g ears to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. ^ Align the hole in the differential pinion shaft with the hole in the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4993 7. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Thread lock and Sealer E0AZ-1955lAA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE M4G20-A2 prior to installation. Install a new differential pinion shaft lock bolt and tighten finger-tight. 8. Using the special tool, install the new differential bearings on the differential case. 9. NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4994 10. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 11. Install the ring gear bolts. ^ Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 12. Install the differential case. Traction-LOK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4995 Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the speed sensor ring, if required. 5. Using the special tools, remove the differential bearing. ^ Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4996 6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. 7. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring. Remove the differential clutch spring. 8. Remove the differential gears. 1 Remove the two differential pinion gears. 2 Remove the two differential side gears. 3 Remove the two differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4997 9. CAUTION: Keep differential clutch packs in order. Do not mix. They must be reassembled in the same sequence. Remove the differential clutch packs and differential side gears and tag them "right" and "left" with the shire. ^ Clean and inspect the remaining parts of the differential case for wear or damage and replace parts as necessary. 10. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Clean and inspect the differential clutch packs for wear and replace parts as necessary. Assembly 1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle. Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C18-A for at least 15 minutes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4998 2. NOTE: Do not mix the differential clutch packs or shims from one side with the other. Assemble the differential clutch packs (without the shims) on the respective differential side gears. 3. CAUTION: Make sure the correct mandrel is used with the special tool. Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge. 4. Position the special tool on top of the differential clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 4999 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut of the special tool over the top and base stud. 7. Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5000 Selective Shims ^ The reading will be the thickness of the new clutch shim. 8. Remove the special tools from the clutch pack and side gear assembly. 9. Install shims on the clutch pack and side gear assembly. 10. Install the differential side gear in the differential case. 11. Install the differential pinion gears with differential pinion thrust washers in the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5001 12. Install the differential clutch spring, using a soft-faced hammer. 13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight. 14. Check the torque required to rotate one differential side gear. ^ Mount the differential case and the special tool in a vise. ^ The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary. 15. Using the special tool, install the differential bearing on the differential case. Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5002 16. NOTE: Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. 17. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 18. Install the ring gear bolts. ^ Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 19. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5003 Differential Case: Service and Repair 9.75 Inch Ring Gear Removal and Installation Removal 1. Remove the differential housing cover and drain the axle. 2. Remove the axle shafts. 3. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage. 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 5. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position the special tool, and inspect ring gear backlash and ring gear backface runout. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5004 6. CAUTION: The bearing caps must be installed in their identical locations and positions. Mark each bearing cap before removal. Loosen the differential case. 1 Remove the bearing cap bolts. 2 Remove the bearing caps. 7. To simplify the installation, fabricate two differential case retaining straps from metal stock as shown. 8. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle! housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the rear axle housing. 9. Remove the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5005 10. CAUTION: Care should be taken not to damage the ring bolt hole threads. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 11. Install the differential case. 1 Position the differential case assembly, including bearing cups and shims, in the carrier. 2 Install the differential bearing caps. 3 Install the differential bearing cap bolts. 12. Position the special tool. 1 Rotate the differential case to make sure the differential bearings seated. 2 Position the special tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5006 13. NOTE: If runout is less than specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. 14. Remove the differential case from the rear axle housing, and remove the differential bearings using the special tool. 15. Using the special tool, install the new differential bearings on the differential case. 16. Measure the differential case runout without the ring gear. ^ Check the case runout again with the new differential bearings. If the runout is now at specification, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5007 1. CAUTION: Make sure that the notches on the case flange and anti-lock speed sensor ring are aligned. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case. 2. Install the ring gear bolts. ^ Apply Stud and Bearing Mount E0AZ-19554BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing. 4. Install a (nominal) shim on the left side. 5. CAUTION: The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cap, is seated. Install the left bearing cap, and loosely install the bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5008 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing Cap, and tighten the bolts. 8. Rotate the differential case to make sure it rotates freely. 9. Using the special tool, measure ring gear backlash. ^ If the backlash is within specification, go to Step 15. The specification shown is the full allowable range. ^ If a zero backlash condition occurs, go to Step 10. ^ If the backlash is not within specification, go to Step 11. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5009 10. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 9. 11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown. ^ If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. 12. Install the bearing caps and bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5010 13. Rotate the differential several times to make sure the differential bearings are correctly seated. 14. Using the special tool, recheck the backlash. ^ If backlash is within specification, go to Step 15. If not, repeat Step 9. ^ The specification shown is the full allowable range. 15. Remove the bearing caps and bolts. ^ To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. ^ Using the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely. 16. Install the bearing caps and bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5011 17. Using the special tool, verify the backlash. 18. Install the axle shafts. Conventional Special Tools Disassembly 1. Remove the differential case. 2. Remove the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5012 3. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the anti-lock speed sensor ring. 5. If required, remove the differential bearings with the special tools. 6. Remove the differential pinion shaft lock bolt and the differential pinion shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5013 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. 8. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Position the differential side gear thrust washers on the differential side gears. ^ Use Motorcraft Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. 2. Position the differential side gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5014 3. Assemble the differential pinion thrust washers and the differential pinion gears. ^ Lubricate with Motorcraft Synthetic Axle Lubricant F1TZ-19580-E3 or equivalent meeting Ford specification WSL-M2C192-A. 4. Engage the differential pinion gears opposite the differential side gears. 5. Using the special tool, install the differential bearings. 6. Rotate the differential pinion gears to align the differential pinion shaft bore. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5015 7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 8. Press the new anti-lock speed sensor ring and the ring gear on the differential case. ^ The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 9. Install the ring gear bolts and lighten. ^ Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 10. Install the differential case. Traction-Lok Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5016 Special Tools Special Tools Disassembly 1. Remove the differential case. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller for Differential Case Bearings and the Step Plate. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5017 2. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. ^ If required, remove the ring gear and anti-lock speed sensor ring. 3. Install the special tool in a suitable vise. 4. Install the differential case on the tool. 5. NOTE: Apply a small amount of grease to the centering hole of the special tool. Install the special tool in the bottom side gear bore. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5018 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the step plate. 7. NOTE: The bar is used to keep the nut from turning when the forcing screw is tightened. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. 8. WARNING: keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert the special tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5019 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs, and tag them RIGHT and LEFT with the shim. 11. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Separate the differential clutch discs and clutch plates for cleaning and inspection. Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5020 1. Prelubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. 2. NOTE: Do not mix the differential clutch packs or shims from one side with the other. NOTE: The Belleville spring is a dished plate. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears. 3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. 4. Position the special tool on top of the differential clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5021 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. 7. NOTE: These shims are available as part of Clutch Pack Replacement Kit F75Z-4947-AA. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.010 inch from the reading to obtain the thickness of the new clutch shim. A maximum of two shims may be used. Select the correct shim(s) size and remove the Traction-LOK Clutch Gauge. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5022 8. Place the shim and Belleville spring on the differential clutch pack. ^ The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case. 9. Refer to the exploded view. ^ Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case. ^ Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case. 10. NOTE: Apply a small amount of grease to the step plate bore. NOTE: if necessary, insert the dowel bar in the nut bore to keep the nut from fuming as the hex screw is tightened. Assemble the forcing screw, nut and step plate to the differential case. 1 Position the step plate in the bottom side gear bore. 2 Position the nut in the top side gear bore and hold it in place. 3 Install the hex-head screw and tighten it two turns after it con facts the bottom step plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5023 11. NOTE: Prelubricate both sides of the differential pinion thrust washers with Motorcraft Synthetic Axle Lubricant F1TZ-19580-E or equivalent meeting Ford specification WSL-M2C192-A. NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth. 12. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate. Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install the differential pinion shaft in the differential case. ^ Install a new differential pinion shaft lock bolt finger-tight. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5024 14. Replace the differential bearings, if removed, using the special tool. 15. Check the torque required to rotate one differential side gear. ^ Install the special tool with the 1/2 inch drive hole, as shown. ^ The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary. 16. Using a press, install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. ^ The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 17. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 00-8-4 > Apr > 00 > Differential Chattering On Turns Differential Clutch: Customer Interest Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 00-8-4 > Apr > 00 > Differential Chattering On Turns > Page 5033 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns Differential Clutch: All Technical Service Bulletins Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns > Page 5039 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Drive Axle Differential Cover: Specifications Front Drive Axle GENERAL SPECIFICATIONS Differential cover bushing gap ....................................................................................................................................................... 1.93 mm (0.076 inch) TORQUE SPECIFICATIONS Differential Housing Cover Bushing Bolt ........................................................................................................................................... 89 Nm (66 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Drive Axle > Page 5044 Differential Cover: Specifications 8.8 Inch Ring Gear TORQUE SPECIFICATIONS Differential Housing Cover Bolts ....................................................................................................................................................... 45 Nm (33 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Drive Axle > Page 5045 Differential Cover: Specifications 9.75 Inch Ring Gear TORQUE SPECIFICATIONS Axle Housing Cover Bolts .................................................................................................................... ................................................ 45 Nm (33 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear Differential Cover: Service and Repair 8.8 Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1 Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing. 2 Remove the differential housing cover. Installation 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the differential housing cover. 2. Apply a new continuous bead of sealant to the differential housing cover. ^ Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5048 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured. Install the differential housing cover. 1 Install the differential housing cover. 2 Install the 10 differential housing cover bolts. 4. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant 6.4-14.3 mm (1/4-9/16 inch) below the bottom of the filler hole. Fill the rear axle with 2.5 - 2.6 liters (5.25 - 5.50 pints) of Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug. ^ For Traction-LOK axles first fill the rear axle with 118 ml (4 oz) of specified Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. 5. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5049 Differential Cover: Service and Repair 9.75 Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning clothe air suspension switch located in the RH kick panel area Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: Empty the lubricant into a clean container for reuse Remove the differential housing cover. 1 Remove the 12 differential housing cover bolts, and drain the lubricant from the rear axle housing. 2 Remove the differential housing cover. Installation 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the differential housing cover. 2. Apply a new, continuous bead of sealant to the differential housing cover. ^ Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A or ESE-14G195-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5050 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured. Install the differential housing cover and tighten the differential housing cover bolts. 4. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole. Fill the rear axle with specified lubricant, and install the filler plug. ^ For Traction-LOK axles, first fill the rear axle with 118 ml (4 ounces) of specified Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. 5. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5054 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5055 Special Tools 1. Remove the front drive axle assembly. 2. Remove the axle housing cover. 1 Remove the drain plug. 2 Drain the differential fluid. 3 Remove the bolts. 4 Remove the differential cover. 3. CAUTION: Fixture mounting bolts must have a minimum thread depth in the carrier. Install the front drive axle assembly in the Bench Mounted Holding Fixture. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5056 4. Unseat the clutch shaft rod boot, and remove the snap ring. 5. Disconnect the front axle actuator motor assembly. 1 Fully extend the front axle actuator motor shaft. 2 Plug the vacuum ports. 3 Pull the front axle actuator motor assembly out. 4 Push the front axle actuator motor assembly away, disconnecting the lever from the slot in the actuator motor shaft. 6. Remove the front axle actuator motor assembly and boot. 1 Remove the boot. 2 Remove the front axle actuator motor assembly. 7. Remove the front axle housing tube assembly. - Reposition the front drive axle assembly in the Bench Mounted Holding Fixture. - Remove the bolts. - Remove the front axle housing tube assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5057 8. Remove the cluster gear clutch thrust washer. 9. Remove the front axle cluster gear. 10. Remove the front axle shaft pilot bearing from the front axle cluster gear. 1 Position the front axle cluster gear in the vise. 2 Use Blind Hole Puller and Slide Hammer to remove the front axle shaft pilot bearing. 11. Lift the front axle shift lever and remove the selector gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5058 12. NOTE: Clearance is provided in casting for roll pin removal. If necessary, remove the shift lever assembly and the shift fork assembly. Drive the manual shaft retaining pin through the shift fork. - Remove the shift lever assembly and the shift fork assembly. 13. Remove the axle shaft. 1 Reposition the carrier assembly in the Bench Mounted Holding Fixture. 2 Remove the axle shaft snap ring. 3 Remove the axle shaft 14. CAUTION: Housing spreader adapter bolts have a minimum thread engagement. Install the left and right Housing Spreader Adapter tools. 15. Position the Carrier Housing Spreader on the spreader adapters. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5059 16. If necessary, adjust the Carrier Housing Spreader to provide clearance for the shift lever. 17. Install the Dial Indicator and Bracketry and position with the tip in the spreader adapter hole. 18. Spread the front axle housing. 1 Adjust the Dial Indicator to zero. 2 Tighten the housing spreader screw until the front axle housing is spread to specification. 3 Remove the Dial Indicator. 19. NOTE: Differential bearing caps must be installed in the original place and position. See reference arrows on differential bearing caps. Remove the differential bearing caps. 1 Remove the bolts. 2 Remove the differential bearing caps and mark or tag them right or left. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5060 20. CAUTION: Wood blocks must be used to avoid front axle housing damage. Remove the differential case from the front axle housing. 1 Position the wood blocks. 2 Use two pry bars and push down on the pry bars. 3 Remove the differential case. 4 Remove Differential Housing Spreader. 21. Mark the front axle universal joint flange and index it to the pinion stem. 1 Reposition the front axle housing in the Bench Mounted Holding Fixture. 2 Mark the front axle universal joint flange and index it to the pinion stem. 22. Install the Companion Flange Holding Tool with bolts, and loosen the pinion nut. 23. With the pinion nut still engaged by a few threads, install the 2-Jaw Puller and remove the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5061 24. Remove the pinion from the carrier housing. 1 Hold the pinion inside the carrier housing. 2 Use a soft face hammer and remove the pinion from the carrier housing. 25. CAUTION: Do not damage the front axle housing while removing the pinion seal. Remove the pinion seal and oil slinger. 26. Use the Puller Tool and the Slide Hammer to remove the inner bearing cup. 27. NOTE: A baffle to aid bearing lubrication is positioned behind the inner bearing cup. Normally this can be left in position if the inner bearing cup is removed. If necessary, remove the baffle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5062 28. Remove the outer axle pinion bearing cup, tapping alternately on each side to prevent the outer axle pinion bearing cup from cocking. 29. Remove the differential pinion bearing. - Install the Pinion Bearing Cone Remover on the differential pinion bearing assembly. - Position the Pinion Bearing Cone Remover and the differential pinion bearing assembly in a press and press the bearing off. 30. NOTE: Measure the drive pinion bearing adjustment shim (which is found under the differential pinion bearing) with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing). Remove the drive pinion bearing adjustment shim from the differential pinion gear. 31. Remove the differential ring gear. - Remove the ten differential ring gear bolts. - Use a drift punch to separate the differential ring gear from the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5063 32. Use the 2-Jaw Puller and the Step Plate to remove the differential bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications Drain Plug: Specifications Drain Plug 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Front Axle Fill Plug: Specifications Front Axle Fill Plug ................................................................................................................................................ .................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Front Axle > Page 5071 Fill Plug: Specifications Rear Axle 8.8 Inch Ring Gear Oil Filler Plug ....................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) 9.75 Inch Ring Gear Oil Filler Plug ....................................................................................................................................... .................................................... 30 Nm (22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential .................................................................................................................................. ................................................................. 1.8 - 2.0L Rear Differential ................................................................................................................................... .................................................................. 2.9 - 3.1L Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5076 Fluid - Differential: Fluid Type Specifications Front Axle ............................................................................................................................................ ............................................................. SAE 75W-90 Rear Axle ............................................................................................................................................. .......................................... SAE 75W-140 Synthetic Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 5077 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle Pinion Bearing: Specifications Differential Bearing Cap Bolts 77 ft.lb Pinion Bearing Torque Preload (Used Pinion Bearing) 8 - 14 in.lb Pinion Bearing Torque Preload (New Pinion Bearing) 16 - 29 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle > Page 5082 Pinion Bearing: Specifications Differential Bearing Cap Bolt 77 ft.lb Pinion Bearing Preload (Used Pinion Bearings) 8 - 14 in.lb Pinion Bearing Preload (New Pinion Bearings) 16 - 29 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Drive Axle > Page 5083 Pinion Bearing: Specifications Differential Bearing Cap Bolt 77 ft.lb Pinion Bearing Preload (Used Pinion Bearing) 8 - 14 in.lb Pinion Bearing Preload (New Pinion Bearing) 16 - 29 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications Pinion Flange: Specifications GENERAL INFORMATION Pinion flange maximum radial runout in assembly .............................................................................. ............................................................................................................... 0.305 mm (0.012 inch T.I.R.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle UNIVERSAL JOINT FLANGE-FRONT Special Tools Removal WARNING: The electrical to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the preload during assembly. 1. Raise and support the vehicle. 2. Remove the front differential support. 1 Remove the nut and bolt. 2 Remove the nuts and bolts. 3 Remove the front differential support. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5089 3. Index-mark the front driveshaft to the axle universal joint flange. 4. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect and support the front driveshaft 1 Remove the four bolts. 2 Carefully disconnect and support the front driveshaft. 5. Using a Nm (inch/pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement for reference during installation. 6. Index-mark the axle universal joint flange to the pinion stem. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5090 7. Install the special tool, and loosen, but do not remove the pinion nut. CAUTION: Before proceeding, place a drain pan under the differential carrier. 8. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear. 9. Inspect the axle universal joint flange for removal damage, burrs, bearing cone contact area damage, and inspect the nut counterbore and the seal contact surface for nicks. Install a new flange if necessary. 10. Check the pinion stem splines for burrs. If burrs are evident, remove them with a fine crocus cloth. Working in a rotating motion, wipe the pinion clean. Installation 1. Lubricate the axle universal joint flange splines and the pinion seal. ^ Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 2. CAUTION: Never install the axle universal joint flange with a hammer or power tools. NOTE: Disregard the scribe marks if installing a new flange. Align the index-marks and position the axle universal joint flange on the pinion shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5091 3. NOTE: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly. Using the special tool, install the axle universal joint flange. 4. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool, and tighten the pinion nut. Refer to the specifications for used bearings. ^ Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch/pound) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to the specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded. 5. Align the index-marks then attach the front driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5092 6. Install the front differential support. 1 Position the differential support. 2 Install the nuts and bolts. 3 Install the nuts and bolts. 7. Inspect and, if necessary, fill the differential. ^ Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 8. Lower the vehicle. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5093 Pinion Flange: Service and Repair 8.8 Inch Ring Gear Special Tools Removal 1. NOTE: The rear wheels and brake discs must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the brake discs. 2. Mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5094 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Using the special tool, hold the pinion flange while removing the pinion nut. 6. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. 7. Using the special tools, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5095 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 3. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. ^ Install a Nm (inch-pound) torque wrench on the pinion nut. ^ Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5096 ^ If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. 6. Position the driveshaft and align the marks on the pinion flange. 7. Install the four driveshaft to pinion flange bolts. 8. Install the brake discs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5097 Pinion Flange: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. NOTE: The rear wheels and brake discs must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the brake discs. 2. Mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5098 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Using a suitable flange holding tool to hold the pinion flange while removing the pinion nut. 6. Mark the driveshaft rear axle pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. 7. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5099 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the rear axle pinion flange with the drive pinion shaft. 3. With the drive pinion in place in the axle housing, install the pinion flange using the special tool. 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using a suitable pinion flange holding tool, hold the pinion flange, tighten the pinion nut. ^ Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. ^ Install a Nm (inch-pound) torque wrench on the pinion nut. ^ Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 5100 ^ If the original recorded arm load is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to Specifications. 6. Position the driveshaft, and align the marks on the pinion flange. 7. Stall the four bolts. 8. Install the brake discs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Tools and Equipment > Front Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Tools and Equipment > Front > Page 5103 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Tools and Equipment > Front > Page 5104 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Pinion Gear: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential Moaning Noise In 2WD Mode Pinion Gear: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Front Drive Axle Pinion Gear: Specifications Front Drive Axle TORQUE SPECIFICATIONS Differential Pinion Shaft Lock Bolt .................................................................................................................................................... 30 Nm (22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5120 Pinion Gear: Specifications 8.8 Inch Ring Gear GENERAL SPECIFICATIONS Pinion maximum runout ...................................................................................................................................................... 0.25 mm (0.010 inch T.I.R.) TORQUE SPECIFICATIONS Differential Pinion Shaft Lock Bolt ...................................................................................................................................................... 30 Nm (22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5121 Pinion Gear: Specifications 9.75 Inch Ring Gear TORQUE SPECIFICATIONS Differential Pinion Shaft Lock Bolt ...................................................................................................................................................... 30 Nm (22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear Pinion Gear: Service and Repair 8.8 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5124 Special Tools Removal 1. Remove the differential case. 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. ^ Wire the driveshaft out of the way. 4. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5125 5. Remove the pinion flange and pinion nut. 6. Install the special tool and, with a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing. ^ Remove the rear axle drive pinion seal. ^ Remove the rear axle drive pinion oil slinger. 7. Use the special tool and a press to remove the pinion bearing cone and roller assembly. 8. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. Remove the outer differential bearing cup with the special tools. 9. Remove the inner differential bearing cup with the special tools. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5126 1. Position the special tools and the inner and outer bearing cups into their respective bores. 1 After placing the inner and outer bearing cups in their bores, place the special tool on the inner pinion gearing cup. 2 Place the special tool on the outer pinion bearing cup. 3 Install the special tool. 2. Tighten the special tool to seat the pinion bearing cups into their bores. 3. NOTE: Steps 3 and 4 are on alternate method of performing Steps 1 and 2. Drive the outer pinion bearing cup into the axle housing using the special tools. 4. Drive the inner pinion bearing cup into the axle housing using the special tools. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5127 5. CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced. Make sure the cups are correctly seated in their bores. ^ If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated. 6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the special tools. 7. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5128 8. NOTE: The special tool must be offset to obtain an accurate reading. Rotate the special tool several half-turns to ensure proper seating of the pinion bearings and position the special tool. 9. Install the special tool. 1 Position the special tool. 2 Install the differential side bearing caps. 3 Install the four differential side bearing cap bolts. 10. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the special tools. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. ^ After the correct shim thickness has been determined, remove the special tools from the axle housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5129 11. Use a press and the special tool to press the pinion bearing and pinion shim until it is firmly seated on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and differential drive pinion collapsible spacer) into the rear axle carrier bore. 14. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal. 1 Install the front pinion bearing cone and rolled 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the special tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5130 15. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C775-B. Place the special tool in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place 16. Lubricate the pinion flange splines. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. 19. Position the new pinion nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5131 20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. ^ Install a Nm (inch-pound) torque wrench on the pinion nut. ^ Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload is obtained. ^ If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. 21. Install the differential case in the rear axle housing. 22. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5132 Pinion Gear: Service and Repair 9.75 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5133 Special Tools Removal 1. Remove the differential case. 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. 4. Using a suitable pin ion flange holding tool, remove the pinion nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5134 5. Remove the pinion flange using the special tool. 6. Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing. 7. Using the special tool, remove the pinion bearing cone and roller assembly. 8. NOTE: Do not remove the pinion bearing cups from the housing unless the cups are damaged. Remove the outer differential bearing cup with the special tools. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5135 9. Remove the inner differential bearing cup with the special tools. Installation 1. Position the special tools and the inner and outer bearing cups in their respective bores. 1 After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup. 2 Place the special tool (outer) on the outer 3 Install the special tool. 2. Tighten the special tool to seat the pinion bearing cups into their bores. 3. NOTE: Steps 3 and 4 are an alternate method of performing Steps 1 and 2. Drive the outer pinion bearing cup into the rear axle housing (4010), using the special tools. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5136 4. Drive the inner pinion bearing cup into the rear axle housing, using the special tools. 5. CAUTION: Whenever the cups are replaced, the differential pinion bearings must also be replaced. Make sure the cups are correctly seated in their bores. ^ If a feeler gauge of the specification shown fin the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated. 6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the Pinion Depth Gauge set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5137 7. NOTE: This step duplicates final pinion bearing preload. Tighten the Driver Handle to He specification. 8. NOTE: The special tool muse be offset to obtain an accurate reading. Rotate the special tool several half-turns to ensure correct seating of the pinion bearings, and position the special tool. 9. Install the special tool. 1 Position the special tool. 2 Install the differential side bearing caps. 3 Install the differential side bearing cap bolts. 10. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5138 rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. ^ After the correct shim thickness has been determined, remove the special tools from the rear axle housing. 11. Using a press and the special tool, press the pinion bearing and pinion shim until they are firmly seated on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. Install the drive pinion in the drive pinion bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer. 14. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal 1 Install the outer pinion bearing cone and roller. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5139 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the special tool. 15. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Use a hammer to install the bearing, rear axle drive pinion seal and rear axle drive pinion shaft oil slinger. 16. Lubricate the pinion flange splines. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1T-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5140 19. Position the new pinion nut. 20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using a suitable pinion flange holding tool, hold the pinion flange, tighten the pinion nut. ^ Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. ^ Install a Nm (inch-pound) torque wrench on the pinion nut. ^ Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. 21. Install the differential case. 22. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Pinion Gear: Tools and Equipment 8.8 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 5143 Special Tools SPECIAL TOOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 5144 Pinion Gear: Tools and Equipment 9.75 Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 5145 Special Tools SPECIAL TOOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle Ring Gear: Specifications Front Drive Axle GENERAL SPECIFICATIONS Ring gear backlash ............................................................................................................................................... 0.203 0.381 mm (0.008 - 0.015 inch) preferred ............................................................................................. .................................................................... 0.305 - 0.381 mm (0.012 - 0.015 inch) Ring gear maximum backface runout ................................................................................................................. 0.102 - 0.004 mm (0.004 - 0.0001 inch) TORQUE SPECIFICATIONS Ring Gear Bolts ................................................................................................................................... .............................................. 105 Nm (77 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5150 Ring Gear: Specifications 8.8 Inch Ring Gear GENERAL SPECIFICATIONS Maximum back face ring gear runout .......................................................................................................................................... 0.102 mm (0.004 inch) Backlash between ring gear and pinion teeth .................................................................. ............................................................................................. 0.203 - 0.381 mm (0.305 - 0.381 mm preferred) ............................................................................................................................................................. 0.008 - 0.015 inch (0.012 - 0.015 inch preferred) Ring gear maximum backlash variation between teeth ..................................................................................................................................................... ........... 0.102 mm (0.004 inch) TORQUE SPECIFICATIONS Ring Gear Bolts ................................................................................................................................... ............................................... 105 Nm (77 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Drive Axle > Page 5151 Ring Gear: Specifications 9.75 Inch Ring Gear GENERAL SPECIFICATIONS Maximum Back Face Ring Gear Runout ....................................................................................................................................... 1.102 mm (0.004 inch) Backlash Between Ring Gear and Pinion Teeth ............................................................................................................................................... 0.203-0.381 mm (0.305-0.381 preferred) ............................................................................................ ...........................................................................0.008-0.015 inch (0.012-0.015 preferred) Ring Gear Maximum Backlash Variation Between Teeth ..................................................................................................................... 0.102 mm (0.004) TORQUE SPECIFICATIONS Ring Gear Bolts ................................................................................................................................... ............................................. 150 Nm (111 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Special Tools Removal 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Remove the pinion seal. Installation 1. Clean the pinion seal bore, and use the Pinion Seal Replacer to install the pinion seal. 2. Install the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5156 Seals and Gaskets: Service and Repair 8.8 Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and remove. Installation 1. Lubricate the new rear axle drive pinion seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace with a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 5157 Seals and Gaskets: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the new rear axle drive pinion seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive 3. Install the pinion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Tools and Equipment > Front Drive Axle Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Tools and Equipment > Front Drive Axle > Page 5160 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Tools and Equipment > Front Drive Axle > Page 5161 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Mechanical Specifications Axle Shaft: Mechanical Specifications Front Wheel Halfshaft and CV Joint Assembled Length 16.43 in Front Wheel Halfshaft and Joint Bolts 51 - 67 ft.lb Maximum Axle Shaft End Play 0.030 in Maximum Axle Shaft End Play 0.030 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Mechanical Specifications > Page 5168 Axle Shaft: Capacity Specifications Lubricant (Outboard) ........................................................................................................................................... ........................................ 165 grams (5.82 ounces) (Inboard) ............................................................ ......................................................................................................................... 235 grams (8.29 ounces) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5169 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5170 Axle Shaft: Diagrams Front Wheel Halfshaft Joints - 1 Of 2 Front Wheel Halfshaft Joints - 2 Of 2 FRONT WHEEL HALFSHAFT JOINTS - DISASSEMBLED VIEW Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5171 Axle Shaft: Description and Operation Front Wheel Halfshaft Joints - 1 Of 2 Front Wheel Halfshaft Joints - 2 Of 2 The halfshaft assembly transmits equal engine torque from the axle to both front wheels. The halfshaft assembly uses a Constant Velocity (CV) joint, at both the inboard and outboard ends, for smooth operation. The CV joints rotate at approximately one-third the speed of a driveshaft and do not normally contribute to any rotational vibration that may occur. The only replaceable components of the halfshaft assembly are: ^ Halfshaft joint boots [inboard and outboard). Replacement kit includes front wheel driveshaft joint boots and clamps, snap rings, retainer ring and grease. ^ Inboard CV joint (plunge type). ^ Side shaft. Replacement includes the outboard front wheel halfshaft joint affixed type), outboard boot and clamps, front wheel excluder seal (assembled on the interconnecting shaft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Symptom Chart(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Testing and Inspection > Symptom Chart(s) > Page 5174 Axle Shaft: Testing and Inspection Halfshafts, Front Wheel NOTE: Constant Velocity (CV) joints must not be replaced unless disassembly and inspection reveals unusual wear. NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. ^ Inspect the boots for evidence of cracks, tears, or splits. ^ Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Removal and Installation Special Tools Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Loosen the lug nuts 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5177 4. Remove the hub nut. 1 Remove the cotter pin. 2 Remove the retainer. 3 Remove the hub nut. 5. Position the front disc brake caliper aside. 1 Remove the two caliper bolts. 2 Lift the front disc brake caliper off the front disc brake caliper anchor plate and position aside. 6. Remove the upper ball joint castle nut. 1 Remove the cotter pin. 2 Remove the castle nut. 7. Use Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5178 8. Remove the six front wheel halfshaft and joint bolts. 9. CAUTION: Use caution to avoid damaging the hub seal when removing the front drive halfshaft. Separate the halfshaft assembly from the hub and remove the halfshaft assembly from the vehicle. Installation 1. Install the six halfshaft bolts. 2. Install the caliper. 1 Position the caliper. 2 Install the caliper bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5179 3. Install the front axle hub. 1 Install the front axle hub nut. 2 Install the retainer. 3 Install the cotter pin. 4. Install the front suspension arm upper ball joint castle nut. 1 Position the front wheel knuckle. 2 Install the upper ball joint castle nut. 3 Install a new cotter pin. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 6. Install the tire and wheel assembly. Disassembly and Assembly Special Tools Disassembly 1. Remove the halfshaft and joint. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5180 2. Slide the two inboard clamp protectors off the boot clamps. 3. CAUTION: Be careful not to damage the front wheel halfshaft joint boot. Remove the two inboard boot clamps. 4. Slide the inboard front wheel halfshaft joint boot off the inboard CV joint housing. 5. Remove the retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5181 6. Remove the inboard CV joint housing. 7. Mark the inner race and the ball cage for assembly. 8. Remove the six balls. 9. Remove the snap ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5182 10. Remove the inner race and ball cage. 11. Remove the inboard front wheel halfshaft joint boot and the clamp protector. 12. Remove the two outboard boot clamps. 1 Remove the outboard clamp protectors. 2 Grip the boot clamps and peel the clamps away from the boot. 13. Remove the outboard front wheel halfshaft joint boot. 14. Inspect for contaminated grease. 15. If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV joint and interconnecting shaft assembly if worn or damaged. Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5183 1. Pack the outboard CV joint with grease. 1 Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit. 2 Spread any remaining grease from service kit evenly inside the outboard boot. 2. Position the outboard front wheel driveshaft joint boot and outboard boot clamps. 1 Clean the front wheel driveshaft joint boot mounting surface. 2 Position the outboard front wheel driveshaft joint boot in the outboard CV joint grooves and position boot clamps. 3. NOTE: Tighten the through-bolt until installer is in the closed position. Use CV Boot Clamp Tool to install the boot clamps. 4. Install the two outboard clamp protectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5184 5. Position the inboard clamp protector and the boot clamp on the halfshaft assembly. 6. Position the inboard front wheel halfshaft joint boot. 7. Position the ball cage on the halfshaft assembly with the tapered end toward the front wheel driveshaft joint boot. 8. NOTE: line up the marks made during disassembly. Position the inner race on the halfshaft assembly with the counterbored end towards the front wheel driveshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5185 9. Install the snap ring. 10. Lubricate and position the six balls. ^ Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-M1C207-A. 11. Position the clamp protector in the inboard boot clamp on the inboard CV joint housing. 12. Fill the inboard CV joint housing with 235 grams of grease. ^ Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-M1C207-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5186 13. Position the inboard CV joint housing and install the retaining ring. 14. Remove any excess grease from the mating surface and position the inboard front wheel halfshaft joint boot. 15. Adjust the CV joint to boot spacing to specification. 16. NOTE: The air should be released only after adjusting the CV joint to boot spacing. Insert a dulled screwdriver blade to relieve built up air pressure in the front wheel halfshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5187 17. Use CV Boot Clamp Tool to install the two inboard boot clamps. 18. Position the clamp protectors over the inboard boot clamps. 19. Install the halfshaft and joint. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5188 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating 8.8 Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover. ^ Drain the lubricant. 4. Remove the brake discs. 5. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Remove the U-washers. 1 Push the axle shafts inboard. 2 Remove the U-washers. 7. CAUTION: Do not damage the inner wheel bearing oil seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5189 Remove the two axle shafts. Installation 1. Lubricate the lip of the inner wheel bearing oil seal ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the inner wheel bearing oil seal Install the two axle shafts. 3. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Install the U-washers. 1 Position the two U-washers on the button end of the axle shafts. 2 Pull the axle shafts outward. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5190 4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install the differential pinion shaft 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. 5. Install the rear brakes. 6. Install the differential housing cover and fill the rear axle housing with the correct amount of specified lubricant. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9.75 Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover. ^ Drain the lubricant. 4. Remove the brake discs. 5. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5191 Remove the U-washers. 1 Push the axle shafts inboard. 2 Remove the U-washers. 7. CAUTION: Do not damage the inner wheel bearing oil seal. Remove the two axle shafts. Installation 1. Lubricate the lip of the inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the inner wheel bearing oil seal. Install the two axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5192 3. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1 Position the two U-washers on the button ends of the axle shafts. 2 Pull the axle shafts outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. 5. Install the brake discs. 6. Install the differential housing cover and fill the rear axle housing with the correct amount of specified lubricant. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5193 Axle Shaft: Tools and Equipment Special Tools Special Tools SPECIAL TOOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5198 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5199 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5200 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5201 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5202 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5203 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5204 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5205 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5206 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5207 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5208 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5209 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5210 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5211 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5212 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5213 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5214 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5215 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5216 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5217 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5218 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5219 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5220 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5221 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5222 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5223 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5224 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5225 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5226 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5227 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5228 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5229 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5230 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5231 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5232 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5233 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5234 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5235 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5236 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5237 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5238 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5239 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5240 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5241 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5242 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5243 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5244 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5245 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5246 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5247 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5248 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5249 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5251 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5252 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5253 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5254 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5255 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5256 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5257 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5258 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5259 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5260 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5261 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5262 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5263 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5264 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5265 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5266 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5267 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5268 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5269 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5270 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5271 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5272 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5273 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5274 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5275 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5276 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5277 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5278 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5279 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5280 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5281 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5282 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5283 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5284 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5285 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5286 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5287 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5288 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5289 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5290 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5291 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5292 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear Wheel Bearing: Specifications 8.8 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear > Page 5295 Wheel Bearing: Specifications 9.75 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5296 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear Wheel Bearing: Service and Repair 8.8 Inch Ring Gear Removal 1. Remove the axle shafts. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5299 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5300 Wheel Bearing: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear axle bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 5301 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 5304 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft Hub Nut 188 - 254 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5323 Drive/Propeller Shaft: Specifications Driveshaft Flange Yoke to Transfer Case Pinion Flange Bolts 70 - 95 ft.lb Driveshaft Slip Yoke to Front Axle Pinion Flange Bolt 70 - 95 ft.lb Driveshaft Flange Yoke to Driveshaft Recur Axle Pinion Flange 70 - 95 ft.lb Front Driveshaft Shield Nut 16 - 20 ft.lb Rear Driveshaft Bolts 33 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation The universal joints (U-joints) connect to each end of the driveshaft and allow for up and down movement of the axles and transmission or transfer case. The U joints are lubricated for the life of the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly Universal Joint: Service and Repair Disassembly and Assembly Double Cardan Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench. 3. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. Mark the positions of the driveshaft components. 4. Clamp the U-Joint Tool in a vise. 5. Remove the eight snap rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5329 6. Remove the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the U-Joint Tool. 2 Press out the bearing cups. 3 Remove the driveshaft slip yoke. 7. Press out the second set of bearing cups. 1 Position the driveshaft slip yoke in the U-Joint Tool. 2 Press out the bearing cup. 3 Rotate the driveshaft slip yoke. 4 Press out the remaining bearing cup. 8. Remove the centering cup spring. 9. Remove the driveshaft center yoke. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5330 1 Position the driveshaft center yoke in the U-Joint Tool. 2 Press out the bearing cup. 3 Rotate the driveshaft center yoke. 4 Press out the remaining bearing cup. Repeat to remove the spider from the driveshaft yoke. Assembly 1. Install a new bearing cup into the driveshaft yoke. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-Joint Tool. 4 Press the bearing cup below the yoke surface. 5 Repeat for the other side of the yoke. 2. Install the driveshaft center yoke. 1 Position the driveshaft center yoke in the U-Joint Tool. 2 Press in a new bearing cup. 3 Rotate the driveshaft center yoke. 4 Press in the other new bearing cup. 3. Install four new snap rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5331 4. Install a new centering cup spring. 5. Install new bearing cups into the driveshaft yokes. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-Joint Tool. 4 Press the bearing cup below the yoke surface. 6. Install four new snap rings. 7. NOTE: Do strike the bearings. Check the U joints for freedom of movement. ^ If bearings are binding, strike the yoke with a plastic hammer. 8. Install the driveshaft. Single Cardan Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5332 Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Mark the positions of the driveshaft components. 4. Clamp the U-Joint Tool in a vise. 5. Remove the snap rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5333 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the U-Joint Tool. 2 Press out a bearing cup. Rotate the driveshaft slip yoke. Press on the spider to remove the remaining bearing cup. Remove the driveshaft slip yoke. 7. Repeat Step 6 to remove the remaining bearing cups, spiders and driveshaft flange yoke from the driveshaft. 8. Clean the yoke area at each end of the driveshaft. Assembly 1. Install the bearing cup. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new Spider in the driveshaft yoke. 3 Position the driveshaft in the U-Joint Tool. 4 Press the bearing cup below the yoke surface. 2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-Joint Tool, and install the snap ring. 3. Repeat Steps 1 and 2 for the opposite side of the driveshaft yoke. 4. Repeat Steps 1 through 3 to install the remaining new bearing cups, spider, driveshaft slip yoke, driveshaft flange yoke and snap rings. 5. NOTE: Do not strike the bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5334 Check the U-Joint for freedom of movement. ^ If binding, strike the yoke with a brass or plastic hammer. 6. If necessary, use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford Specification ESA-M1C75-B to lubricate the U joints. 7. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5335 Universal Joint: Service and Repair Indexing NOTE: If driveshaft components are replaced and driveshaft vibration is encountered after installation, index the driveshaft. NOTE: If indexing the driveshaft does not eliminate the vibration, balance the driveshaft. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the driveshaft. 3. Rotate the rear axle flange. 4. Connect the driveshaft. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle and test drive it. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5336 Universal Joint: Service and Repair Runout and Balance 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearing. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen but do not remove the lug nuts. 2. WARNING: electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Use a twain post axle contact hoist to raise and support the vehicle. 3. Remove the tire and wheel assembly. 1 Remove the lug nuts. 2 Remove the tire and wheel assembly. 4. Install the lug nuts to retain the brake discs. 5. CAUTION: To prevent overheating, do not run the vehicle on the hoist for an extended period. Note and record the baseline speed. ^ With the transmission in gear, increase the vehicle speed to the maximum vibration level. Note and record the speed of this vibration period as a baseline speed. 6. Check the attachment of the driveshaft to the rear axle flange. Replace any worn parts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 5337 7. WARNING: keep hands away from the balance weights while the driveshaft is rotating. Check the driveshaft for out of balance. 1 With the transmission in gear, run the vehicle with the speedometer indicating 680 km (40 - 50 mph) 2 Have an assistant barely contact the driveshaft with a marker in the rear, middle, and front ends to indicate heavy spots. 8. Balance the driveshaft. 1 Install two stainless steel screw-type hose clamps on the driveshaft with the clamp screws opposite the mark. 2 Tighten the hose clamps starting at the pinion yoke end of the driveshaft. 9. Run the vehicle at 680 km (40 - 50 mph). 10. If the vibration is still evident, rotate the clamps away from each other until balanced and test. 11. If necessary, continue to rotate the clamps apart in smaller increments and test. If the vibration still exists, repeat the procedure at the front of the driveshaft. 12. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug nuts. 3 Lower the vehicle and tighten the lug nuts. 4 Install the center cap. 13. Road test the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 5338 Universal Joint: Tools and Equipment SPECIAL TOOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts Stage 1 Loosely install bolts Stage 2 54-64 ft.lb -- In sequence Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5342 Flex Plate: Service and Repair Removal 1. Remove the transmission. 2. Remove the bolts. Installation 1. Position the flywheel and install the bolts tighten the bolts in two stages. ^ Stage 1: Loosely install the bolts. ^ Stage 2: Tighten the bolts in sequence shown. 2. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications Shift Indicator: Specifications Transmission Column Shift Selector Tube Bracket Bolts ........................................................................................................................ 14 Nm (10 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications > Page 5348 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. ^ Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. ^ Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5361 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5367 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Page 5368 Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service Precautions Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal capacity. This may cause fluid foaming and transmission damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5379 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5380 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5385 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5386 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5387 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5388 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5389 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5390 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5391 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5392 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5393 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5394 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5395 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5396 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5399 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5400 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5401 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5402 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5403 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5404 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5405 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5406 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5407 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5408 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5409 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5411 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5412 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5413 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5414 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5415 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5416 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5417 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5418 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5419 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5420 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5421 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5422 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5423 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5424 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5425 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5426 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5427 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5428 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5430 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5433 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5434 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5435 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5436 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5437 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5438 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5439 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5440 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5441 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5442 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5443 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5444 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5445 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5446 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5447 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5448 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5449 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5450 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5451 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5452 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5453 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5454 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5456 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5457 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5458 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5459 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5460 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5461 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5462 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5464 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5465 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5466 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5467 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5468 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5469 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5470 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5471 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5472 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5473 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5474 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5475 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5476 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5477 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5478 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5479 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5485 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5486 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5497 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5498 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5504 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5505 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5506 Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5507 Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay The Torque On Demand Relay is located behind center of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 5512 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5513 Four Wheel Drive Selector Relay: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5519 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5523 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5524 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5525 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5526 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5527 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 5533 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 5534 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5541 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5542 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift motor bolts ................................................................................................................................... ........................................... 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5558 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5559 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5560 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5561 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5564 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5565 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5566 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5567 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5576 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5577 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5583 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5584 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5593 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5594 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5600 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5601 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5602 Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5603 Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity Transfer Case Fluid ............................................................................................................................. ........................................................................... 1.9L Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 5608 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid ............................................................................................................................. ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 5609 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 5610 Fluid - Transfer Case: Service and Repair 1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: The fluid level must be just below the fill plug. Remove the fill plug and check the fluid level. ^ If the fluid is below the proper level, fill the transfer case with Motorcraft MERCON Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON equivalent. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5619 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5625 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Page 5626 Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay The Torque On Demand Relay is located behind center of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 5631 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5632 Four Wheel Drive Selector Relay: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5648 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5654 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Page 5665 Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5675 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5676 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5682 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5683 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5684 Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5685 Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay The Torque On Demand Relay is located behind center of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 5690 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5691 Four Wheel Drive Selector Relay: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: Index-mark the rear driveshaft yoke and pinion flange to maintain initial driveshaft balance during installation. Remove the rear driveshaft. 3. Using a suitable tool, remove the oil seal. Installation 1. To install, reverse the removal procedure. ^ Using the special tool, install the oil seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 5695 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift motor bolts ................................................................................................................................... ........................................... 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5712 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5713 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5714 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5715 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5718 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5719 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5720 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5721 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5728 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5732 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. ^ Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80 - 100 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift motor bolts ................................................................................................................................... ........................................... 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5740 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5741 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5742 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5743 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5746 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5747 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5748 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5749 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications Shift Indicator: Specifications Transmission Column Shift Selector Tube Bracket Bolts ........................................................................................................................ 14 Nm (10 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Specifications > Page 5755 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. ^ Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. ^ Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5768 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5774 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Page 5775 Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5786 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5787 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5793 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5794 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5795 Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5796 Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay The Torque On Demand Relay is located behind center of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 5801 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5802 Four Wheel Drive Selector Relay: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5808 Transmission Mode Switch: Service and Repair TRANSMISSION MODE SWITCH Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) Sensor Bolts 68 - 89 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5812 Transmission Position Switch/Sensor: Diagrams 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR CONNECTOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5813 Transmission Position Switch/Sensor: Testing and Inspection 1 Of 2 2 Of 2 DIGITAL TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5814 Transmission Position Switch/Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 4. Disconnect the digital TR electrical connector. 5. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 6. Loosen the digital TR bolts. 7. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5815 Use digital Transmission Range (TR) Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. 8. Tighten the bolts. 9. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 10. With the manual lever in overdrive connect the shift lever control cable. 11. Install the digital TR sensor electrical connector. 12. Lower the vehicle. 13. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 5822 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Front > Page 5823 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) Bolt 98 - 115 in.lb Output Shaft Speed (OSS) Sensor Bolt 6 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front Transmission Speed Sensor: Service and Repair Front Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 3. Remove the front: output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the glass. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5830 Transmission Speed Sensor: Service and Repair Rear Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. ^ Use the proper electrical connector pin remover. 4. Remove the boll, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Front > Page 5831 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations The 4WABS relay is located in the battery junction box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5853 Electronic Brake Control Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5855 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the ABS module. 4. Remove the anti-lock brake control module. 1. Remove the screws. 2. Remove the anti-lock brake control module. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5856 1. CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TORQUE SPECIFICATIONS EHCU Bolts To Lower Bracket ................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) EHCU Bracket Bolts To Frame ................................................................................................................................................. 26-31 Nm (19-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5860 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water anal induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the hydraulic brake lines. 1. Disconnect the inlet hydraulic brake lines. 2. Disconnect the outlet hydraulic brake lines. 4. Remove the Hydraulic Control Unit (HCU). 1. Remove the bolts. 2. Remove the HCU. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5861 5. If necessary, remove the HCU bracket. 1. Remove the bolts. 2. Remove the HCU bracket. Installation 1. If removed, install the HCU bracket. 1. Position the bracket. 2. Install the HCU bracket bolts. 2. Install the HCU. 1. Position the HCU. 2. Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5862 3. CAUTION: Only authorized Ford inlet hydraulic brake lines should be used. These lines are of specific design and should only be replaced with authorized Ford parts. Connect the hydraulic brake lines. 4. Connect the anti-lock brake control module electrical connectors. 5. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Connect the battery ground cable. 6. Bleed the brake hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 9 ft.lb Front ABS Sensor Wire Bracket Bolt 62-80 in.lb Rear Anti-Lock Brake Sensor Bolt 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Removal 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front anti-lock brake sensor bolts and the (B) front anti-lock brake sensor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5868 Wheel Speed Sensor: Service and Repair Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1. Disconnect the rear anti-lock brake sensor electrical connector. 2. Remove the bolt. 3. Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removed procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding Brake Bleeding: Service and Repair Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has be en drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5873 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5874 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for IS minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5875 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with c lean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5876 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding cooperation. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5877 5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5878 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: This procedure must be performed if the 4 Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been installed new. NOTE: One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal. NOTE: Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. NOTE: Add recommended brake fluid as necessary throughout the procedure. 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. Have an assistant pump the brake pedal and then hold film pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5879 5. A Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. 6. NOTE: Go to the help menu in the NGS Tester. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the NGS instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the NGS service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications TORQUE SPECIFICATIONS Brake Pedal Bracket Nuts and Bolt ............................................................................................................................................ 21-29 Nm (17-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions Brake Pedal Assy: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Brake Pedal Assy: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Brake Pedal Assy: Electrical Diagrams Diagram 127-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 Diagram 127-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Diagram 127-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page 5902 Brake Pedal Assy: Description and Operation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. The brake pedal is adjustable, either non-memory or memory is available. When the brake pedal is depressed, brake fluid is pushed from the master cylinder through the metal tubing and flexible hoses to the rear disc brake calipers and the front disc brake calipers. The brake fluid enters the rear disc brake calipers, forcing the rear disc brake caliper pistons outward against the brake pads. The brake pads press against the braking surface on the brake discs. The front disc brake caliper pistons are forced outward against the brake pads, and contact the braking surface of the brake discs and hub. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake shoes and linings to the unapplied position. The dual brake system is split front and rear with the front wheel brakes comprising one circuit and the rear wheel brakes, the other circuit. The ability of a brake system to stop the vehicle is dependent on the available traction. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Testing and Inspection > DSM Diagnostic Trouble Code (DTC) Index Brake Pedal Assy: Testing and Inspection DSM Diagnostic Trouble Code (DTC) Index Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Testing and Inspection > DSM Diagnostic Trouble Code (DTC) Index > Page 5905 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Testing and Inspection > DSM Diagnostic Trouble Code (DTC) Index > Page 5906 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Testing and Inspection > DSM Diagnostic Trouble Code (DTC) Index > Page 5907 Brake Pedal Assy: Testing and Inspection Parameter Identification (PID) Index Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket Brake Pedal Assy: Service and Repair Adjustable Pedal and Bracket Removal 1. CAUTION: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new pedal. The pedals must be in the all the way forward or all the way rearward position. Disconnect the battery ground cable. 2. Remove the instrument panel opening cover. 3. Remove the steering column support bracket. 1. Remove the nuts. 2. Remove the steering column support bracket. 4. Remove the stoplight switch self-lock pin. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5910 5. Slide the stoplight switch, booster push rod and the bushing off the brake pedal pin. 6. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal by squeezing the exposed tongs with a pair of pliers and simultaneously pulling on the clip. 7. Disconnect the brake pedal motor electrical connector. 8. Remove the bulkhead sound insulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5911 9. Remove the brake pedal bracket nuts. 10. Remove the brake pedal bracket bolts, and remove the brake pedal and bracket. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5912 1. Install the brake pedal bracket bolts. 2. Install the brake pedal bracket and nuts. 3. Install the bulkhead sound insulator. 4. Connect the brake pedal motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5913 5. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. 6. CAUTION: When installing the brake pedal-to-accelerator pedal cable, the brake pedal and the accelerator pedal must be in the same position, all the way forward or all the way rearward. Position the accelerator pedal using the brake pedal motor, all the way forward or backward, depending on the position of the new brake pedal. 7. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal. By squeezing the exposed tangs with a pair of pliers and simultaneously pulling on the clip. 8. Position the brake pedal in the same position as the accelerator pedal, using the brake pedal motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5914 9. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. 10. When installing a new accelerator pedal, the accelerator pedal will come in the forward or rearward position. Before installing the cable, move the brake pedal with the motor so it is in the same position as the accelerator pedal. 11. Slide the stoplight switch, booster push rod and the bushing on the brake pedal pin. 12. Install the stoplight switch self-locking pin. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5915 13. Install the steering column support bracket. 14. Install the instrument panel opening cover. 15. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5916 Brake Pedal Assy: Service and Repair Brake Pedal Motor Removal 1. Disconnect the brake pedal motor electrical connector. 2. Remove the brake pedal motor bolts. Installation 1. NOTE: Hand-tighten bolts. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5917 Brake Pedal Assy: Service and Repair Brake Pedal Motor Cable Removal 1. Disconnect the brake pedal motor electrical connector. 2. Remove the brake pedal motor bolts. 3. Remove the brake pedal to motor cable. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5918 Brake Pedal Assy: Service and Repair Removal and Installation Removal 1. CAUTION: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new pedal. The pedals must be in the all the way forward or all the way rearward position. Disconnect the battery ground cable. 2. Remove the instrument panel opening cover. 3. Remove the stoplight switch self-locking pin. 4. Slide the stoplight switch, booster push rod and the bushing off the brake pedal pin. 5. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5919 6. Disconnect the brake pedal motor electrical connector. 7. Unload the pedal spring. 8. Remove the brake pedal nut. 9. Remove the brake pedal bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5920 10. Remove the brake pedal. Installation 1. Install the brake pedal. 2. Make sure bushings are in the end of the pivot tube. 3. Install the brake pedal bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5921 4. Install the brake pedal nut. 5. Load the pedal spring. 6. Connect the brake pedal motor electrical connector. 7. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5922 8. CAUTION: When installing the brake pedal-to-accelerator pedal cable, the brake pedal and the accelerator pedal must be in the same position, all the way forward or all the way rearward. Position the accelerator pedal using the brake pedal motor, all the way forward or backward depending on the position of the new brake pedal. 9. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal, by squeezing the exposed tangs with a pair of pliers and simultaneously pulling on the clip. 10. Position the brake pedal in the same position as the accelerator pedal, using the brake pedal motor. 11. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. 12. If installing a new accelerator pedal, the accelerator pedal will come in the forward or rearward position. Before installing the cable, move the brake pedal with the motor so it is in the same position as the accelerator pedal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5923 13. Slide the stoplight switch, booster push rod and the bushing on the brake pedal pin. 14. Install the stoplight switch self-locking pin. 15. Install the instrument panel opening cover. 16. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5924 Brake Pedal Assy: Service and Repair Standard Pedal and Bracket Removal 1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be required for installation. Disconnect the brake booster push rod. 1. Remove the hairpin clip. 2. Separate the stoplight switch and the brake booster push rod from the brake pedal pin. 3. Remove the brake booster push rod bushing. 2. Remove the bulkhead sound insulator. 3. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5925 4. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Remove the brake pedal assembly. 1. Remove the nuts. 2. Remove the brake pedal assembly. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Adjustable Pedal and Bracket > Page 5926 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper Bleeder Screw 9-13 ft.lb Caliper Bolts 21-26 ft.lb Caliper Anchor Plate Bolts 126-169 ft.lb Rear Caliper Bleeder Screw 12-18 ft.lb Brake Caliper Bolts 20 ft.lb Disc Brake Adapter Nuts 40 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Brake Caliper: Service and Repair Brake Caliper Bracket Removal 1. Disconnect the parking brake rear cable and conduit. 2. Remove the axle shaft. 3. Remove the parking brake shoe and linings. 4. Remove the nuts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5936 Brake Caliper: Service and Repair Front Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate 1. Position the front disc brake caliper anchor plate 2. Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5937 1. Place a block of wood between the caliper bridge and the caliper pistons. 2. Apply low air pressure to the fluid port in the disc brake caliper. 3. Force out the caliper pistons to the block of wood. 4. Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper. Assembly CAUTION: Never reuse piston seals and dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5938 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1. Install the piston seal. 2. Install the piston boot on the caliper piston. 3. CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4. CAUTION: Be careful not to cock the caliper piston. Press the caliper piston into the cylinder bore. 3. Install the disc brake caliper. Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. the bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5939 Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly. 4. CAUTION: Replace the lining if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Inspect the pads for wear or contamination. 5. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting, get medical attention immediately. Disconnect the front brake hose. 1. Remove the front brake hose bolt. 2. Disconnect the front brake hose. 3. Remove the copper washers. Plug the front brake hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5940 6. Remove the disc brake caliper. 1. Remove the two caliper bolts using a T45 Torx(R). 2. Lift the disc brake caliper off the front disc brake caliper anchor plate. 7. On 4x2 vehicles, measure the brake disc thickness. - Replace the brake disc and hub if not within specification. 8. On 4x4 vehicles, measure the brake disc thickness. - Replace the brake disc if not within specification. 9. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5941 1. Install the disc brake caliper. 1. Install the disc brake caliper. 2. Install the front disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers to connect the front brake hose. - Install the front brake hose bolt. 3. Bleed the front disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Install the tire and wheel assembly. 6. Install the center cap. 7. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Inspect the brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5942 Brake Caliper: Service and Repair Rear Disassembly and Assembly Special Tools Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the caliper piston. 1. Place a block of wood between the caliper bridge and the caliper piston. 2. Apply low air pressure to the fluid port in the rear disc brake caliper. 3. Force out the caliper piston to the block of wood. 4. Remove the block of wood and the caliper piston. 5. NOTE: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. Remove and discard the piston seal and dust boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5943 Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid Hat has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 1. Lubricate the following with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Cylinder bore. - Piston seal. - Caliper piston. - Dust boot. 2. Install the piston seal. 3. Install the dust boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5944 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the caliper piston. 5. Install the rear disc brake caliper. Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. WARNING: Occupational Safety And Health Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 1[ his can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. CAUTION: Replace the brake pads in complete axle sets. Inspect the brake pads for wear or contamination. Replace the brake pads if worn to or past specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5945 4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1. Remove the bolt. 2. Disconnect the rear wheel brake hose. 3. Remove the copper washers, and plug the brake hose. 5. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1. Remove the brake caliper bolts. 2. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 6. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5946 7. Measure the brake disc thickness. - Replace the brake disc if not within specification. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. - Use new copper washers; connect the brake hose and install the caliper flow bolt. 3. Bleed the rear disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel, wheel hub, or brake disc. Any debris on the wheel mounting surfaces can cause the lug nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 6. Verify proper brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Min. Thickness Above Backing Plate Or Rivets 0.039 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5952 4. CAUTION: Replace the lining if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Inspect the pads for wear or contamination. 5. CAUTION: When removing the front disc brake caliper, never allow it to hang from a brake hose. Provide a suitable support. Remove the disc brake caliper. 1. Remove the caliper bolts using a T45 Torx(R). 2. Lift the disc brake caliper off the front disc brake caliper anchor plate. 6. On 4x2 vehicles, measure the brake disc thickness. - Replace the brake disc and hub if not within specification. 7. On 4x4 vehicles, measure the brake disc thickness. - Replace the brake disc if not within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5953 8. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. 9. Remove the disc brake anti-rattle clips. 1. Remove the pads. 2. Remove the disc brake anti-rattle clips. Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the front brake pad lining material. Do not install contaminated pads. Install the pads. 1. Install the disc brake anti-rattle clips. 2. Install the pads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5954 2. CAUTION: Use care not to damage the bleeder screw or front wheel disc brake shield. Install the disc brake caliper. 1. Install the disc brake caliper. 2. Install the disc brake caliper bolts. 3. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 4. Install the tire and wheel assembly. 5. Install the center cap. 6. NOTE: If equipped with air suspension reactivate the system by turning on the air suspension switch. Inspect the brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5955 Brake Pad: Service and Repair Rear Removal 1. NOTE: It is not necessary to remove the hydraulic brake line when performing this procedure. Remove the rear disc brake caliper. 2. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 3. Retract the caliper piston into the rear disc brake caliper. 4. Remove the slippers. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5956 1. Install the slippers. 2. CAUTION: The brake pads should be replaced in full axle sets only. Do not replace the worn brake pads on only one side of the vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify proper brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brake Rotor - Incorrect Discard Thickness Specification Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Incorrect Discard Thickness Specification Article No. 99-25-6 12/13/99 ^ BRAKES - INCORRECT ROTOR THICKNESS STAMPED ON ROTOR - F-150 4X2 ONLY ^ BRAKES - INCORRECT WORKSHOP MANUAL ROTOR DISCARD THICKNESS SPECIFICATION FORD: 1997-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-2000 NAVIGATOR ISSUE The 1997-2000 Workshop Manuals do not provide the correct and complete specification for rotor discard thickness. Additionally, some 4X2 F-150 rotors may have an incorrect rotor discard thickness stamped on them. Updated Information Per TSB 99-25-6 ACTION Refer to the Front and Rear Disc Rotor Discard Specification Charts for correct rotor discard specification. * SOME 4X2 F-150 ROTORS SHOW "24.7 mm" PRINTED ON THE ROTOR BACK SIDE. THIS IS AN ERROR, THESE CAN BE CUT TO 24.5 mm DISCARD THICKNESS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 390000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc Front Min. Disc Thickness (Discard Thickness) 1.09 in Rear Brake Disc Min. Thickness 0.47 in Max. Brake Disc Runout 0.0002 in Max. Brake Disc Thickness Variation 0.0005 in Front Min. Disc Thickness (Discard Thickness) 1.09 in Rear Brake Disc Min. Thickness 0.47 in Max. Brake Disc Runout 0.0002 in Max. Brake Disc Thickness Variation 0.0005 in Front Min. Disc Thickness (Discard Thickness) 1.09 in Rear Brake Disc Min. Thickness 0.75 in Max. Brake Disc Runout 0.0002 in Max. Brake Disc Thickness Variation 0.0005 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 5963 Brake Rotor/Disc: Specifications Disc Backing Plate TORQUE SPECIFICATIONS Brake Disc Shield Screws ..................................................................................................................................................... 10-14 Nm (89-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc Brake Rotor/Disc: Service and Repair Brake Rotor/Disc Front Removal 1. Remove the front disc brake caliper anchor plate. 2. On 4x4 vehicles, remove the brake disc. - If necessary, resurface the brake disc. Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's instructions. 3. On 4x2 vehicles, remove the brake disc and hub as follows: 1. Remove the hub grease cap. 2. Remove the cotter pin. 3. Remove the nut retainer. 4. Remove the spindle nut. 5. Remove the front wheel outer bearing retainer washer). 6. Remove the outer front wheel bearing. 7. Remove the brake disc and hub. 4. If necessary on 4x2 vehicles, resurface the brake disc and hub. Ford recommends on-vehicle brake disc machining. Follow the lathe manufacturer's instructions. 1. Remove the wheel hub grease seal. 2. Remove the inner front wheel bearing. Installation 1. On 4x4 vehicles, position the brake disc. 1. Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. - Clean the brake disc. 2. Position the brake disc. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5966 2. On 4x2 vehicles, use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to thoroughly clean and inspect the front wheel bearings and the brake disc and hub. 3. On 4x2 vehicles, lubricate the front wheel bearings. - Use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford specification ESA-M1C198-A. 4. On 4x2 vehicles, install a new wheel hub grease seal. 1. Install the inner front wheel bearing. 2. Install a new wheel hub grease seal. 5. On 4x2 vehicles, install the brake disc and hub. 1. Position the brake disc and hub. 2. Install the outer front wheel bearing. 3. Install the front wheel outer bearing retainer washer. 4. Install the spindle nut. 6. NOTE: On 4x2 vehicles, rotate the brake disc and hub while adjusting front wheel bearing end play. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5967 Tighten the spindle nut. 7. Loosen the spindle nut two turns. 8. Tighten the spindle nut while rotating the brake disc counterclockwise. 9. Loosen the spindle nut. 10. Tighten the spindle nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5968 11. On 4x2 vehicles, install the following components: 1. nut retainer 2. cotter pin 3. hub grease cap 12. Install the front disc brake caliper anchor plate. Rear Removal 1. NOTE: When removing the rear disc brake caliper in this procedure, it is not necessary to disconnect the rear wheel brake hose. Remove the rear disc brake caliper. 2. NOTE: If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole access plug and contract the parking brake shoe and lining. Remove the brake disc. 1. Remove the press-on keeper nuts, if so equipped. 2. Remove the brake disc. 3. Inspect the brake disc. - Replace the brake disc if not within specification. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5969 1. Install the brake disc. 2. Install the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5970 Brake Rotor/Disc: Service and Repair Disc Backing Plate Front Removal 1. Remove the brake disc. 2. On 4x4 vehicles, remove the wheel hub. 3. On 4x2 vehicles, remove the brake disc shield. 1. Remove the brake disc shield screws. 2. Remove the brake disc shield. 4. On 4x4 vehicles, remove the brake disc shield. 1. Remove the screws. 2. Remove the brake disc shield. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5971 1. Follow the removal procedure in reverse order. Rear Removal 1. Remove the rear wheel disc brake adapter. 2. Remove the rear wheel disc brake shield. 1. Drill out the rivets. 2. Remove the rear wheel disc brake shield. Installation 1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, new rivets are not required. Seal the rivet holes with Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding Brake Bleeding: Service and Repair Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has be en drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5977 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. - Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5978 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for IS minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5979 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with c lean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5980 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding cooperation. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5981 5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5982 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: This procedure must be performed if the 4 Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been installed new. NOTE: One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal. NOTE: Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. NOTE: Add recommended brake fluid as necessary throughout the procedure. 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. Have an assistant pump the brake pedal and then hold film pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Gravity Bleeding > Page 5983 5. A Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. 6. NOTE: Go to the help menu in the NGS Tester. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the NGS instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the NGS service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper Bleeder Screw 9-13 ft.lb Caliper Bolts 21-26 ft.lb Caliper Anchor Plate Bolts 126-169 ft.lb Rear Caliper Bleeder Screw 12-18 ft.lb Brake Caliper Bolts 20 ft.lb Disc Brake Adapter Nuts 40 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Brake Caliper: Service and Repair Brake Caliper Bracket Removal 1. Disconnect the parking brake rear cable and conduit. 2. Remove the axle shaft. 3. Remove the parking brake shoe and linings. 4. Remove the nuts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5989 Brake Caliper: Service and Repair Front Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate 1. Position the front disc brake caliper anchor plate 2. Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5990 1. Place a block of wood between the caliper bridge and the caliper pistons. 2. Apply low air pressure to the fluid port in the disc brake caliper. 3. Force out the caliper pistons to the block of wood. 4. Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper. Assembly CAUTION: Never reuse piston seals and dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5991 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1. Install the piston seal. 2. Install the piston boot on the caliper piston. 3. CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4. CAUTION: Be careful not to cock the caliper piston. Press the caliper piston into the cylinder bore. 3. Install the disc brake caliper. Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. the bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5992 Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly. 4. CAUTION: Replace the lining if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Inspect the pads for wear or contamination. 5. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting, get medical attention immediately. Disconnect the front brake hose. 1. Remove the front brake hose bolt. 2. Disconnect the front brake hose. 3. Remove the copper washers. Plug the front brake hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5993 6. Remove the disc brake caliper. 1. Remove the two caliper bolts using a T45 Torx(R). 2. Lift the disc brake caliper off the front disc brake caliper anchor plate. 7. On 4x2 vehicles, measure the brake disc thickness. - Replace the brake disc and hub if not within specification. 8. On 4x4 vehicles, measure the brake disc thickness. - Replace the brake disc if not within specification. 9. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5994 1. Install the disc brake caliper. 1. Install the disc brake caliper. 2. Install the front disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers to connect the front brake hose. - Install the front brake hose bolt. 3. Bleed the front disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Install the tire and wheel assembly. 6. Install the center cap. 7. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Inspect the brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5995 Brake Caliper: Service and Repair Rear Disassembly and Assembly Special Tools Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the caliper piston. 1. Place a block of wood between the caliper bridge and the caliper piston. 2. Apply low air pressure to the fluid port in the rear disc brake caliper. 3. Force out the caliper piston to the block of wood. 4. Remove the block of wood and the caliper piston. 5. NOTE: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. Remove and discard the piston seal and dust boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5996 Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid Hat has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 1. Lubricate the following with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Cylinder bore. - Piston seal. - Caliper piston. - Dust boot. 2. Install the piston seal. 3. Install the dust boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5997 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the caliper piston. 5. Install the rear disc brake caliper. Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. WARNING: Occupational Safety And Health Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 1[ his can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. CAUTION: Replace the brake pads in complete axle sets. Inspect the brake pads for wear or contamination. Replace the brake pads if worn to or past specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5998 4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1. Remove the bolt. 2. Disconnect the rear wheel brake hose. 3. Remove the copper washers, and plug the brake hose. 5. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1. Remove the brake caliper bolts. 2. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 6. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket > Page 5999 7. Measure the brake disc thickness. - Replace the brake disc if not within specification. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. - Use new copper washers; connect the brake hose and install the caliper flow bolt. 3. Bleed the rear disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel, wheel hub, or brake disc. Any debris on the wheel mounting surfaces can cause the lug nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 6. Verify proper brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 6003 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: - Eye Contact - rinse eyes thoroughly with water. - Skin Contact - wash skin with soap and water. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose Brake Hose/Line: Specifications Brake Hose TORQUE SPECIFICATIONS Front Brake Hose Bolt ......................................................................................................................... ...................................... 30-40 Nm (23-29 ft. lbs.) Brake Hose Bracket To Front Suspension Lower Arm Screw .................................................................................................................................... 13-17 Nm (10-13 ft. lbs.) Rear Caliper Flow Bolt .............................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) Left Rear Brake Hose Bracket Bolt ........................................................................................................................................... 13-17 Nm (10-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 6011 Brake Hose/Line: Specifications Brake Line TORQUE SPECIFICATIONS 1/2-20 And 9/16-18 Brake Lines ................................................................................................................................................ 21-29 Nm (15-21 ft. lbs.) 7/16-24 Brake Lines ............................................................................................... .................................................................... 15-20 Nm (11-14 ft. lbs.) Front Master Cylinder Brake Tube ............................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Tube ............................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose Brake Hose/Line: Description and Operation Brake Hose CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new Ford authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic lines between the brake master cylinder and the hydraulic control unit. Steel tubing is used between the hydraulic control unit and the front and rear hoses. Double flared brake tubing should provide good leakproof connections. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose > Page 6014 Brake Hose/Line: Description and Operation Brake Line CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new Ford authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic lines between the brake master cylinder and the hydraulic control unit. Steel tubing is used between the hydraulic control unit and the front and rear hoses. Double flared brake tubing should provide good leakproof connections. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications TORQUE SPECIFICATIONS Brake Master Cylinder Fluid Control Valve .............................................................................................................................. 30-49 Nm (22-36 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6018 Brake Proportioning/Combination Valve: Description and Operation Brake Master Cylinder Fluid Control Valve The brake master cylinder fluid control valve regulates the hydraulic pressure in the rear brake system. It is located on the brake master cylinder and is screwed into the rearmost outlet port. When the brake pedal is applied, the full brake pressure passes through the brake master cylinder fluid control valve to the rear brake system until the valve's split point is reached. Above its split point, the brake master cylinder fluid control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lockup during hard braking. In the case of front brake system malfunction, the brake master cylinder fluid control valve has a bypass feature which allows full hydraulic pressure to the rear brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6019 Brake Proportioning/Combination Valve: Service and Repair Removal Remove Brake Master Cylinder Fluid Control Valve 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. NOTE: Do not attempt to service the control valve. It is serviced only as an assembly. Remove the brake master cylinder fluid control valve. 1. Disconnect and plug the brake line. 2. Remove the brake master cylinder fluid control valve. Installation Install Brake Master Cylinder Fluid Control Valve 1. Follow the removal procedure in reverse order. - Bleed the rear brakes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TORQUE SPECIFICATIONS EHCU Bolts To Lower Bracket ................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) EHCU Bracket Bolts To Frame ................................................................................................................................................. 26-31 Nm (19-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6023 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water anal induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the hydraulic brake lines. 1. Disconnect the inlet hydraulic brake lines. 2. Disconnect the outlet hydraulic brake lines. 4. Remove the Hydraulic Control Unit (HCU). 1. Remove the bolts. 2. Remove the HCU. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6024 5. If necessary, remove the HCU bracket. 1. Remove the bolts. 2. Remove the HCU bracket. Installation 1. If removed, install the HCU bracket. 1. Position the bracket. 2. Install the HCU bracket bolts. 2. Install the HCU. 1. Position the HCU. 2. Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6025 3. CAUTION: Only authorized Ford inlet hydraulic brake lines should be used. These lines are of specific design and should only be replaced with authorized Ford parts. Connect the hydraulic brake lines. 4. Connect the anti-lock brake control module electrical connectors. 5. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Connect the battery ground cable. 6. Bleed the brake hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect Technical Service Bulletin # 98S32 Date: 981201 Recall - Brake Pedal Pushrod Retainer Defect SAFETY RECALL 98S32 Certain 1999 Expedition and Lincoln Navigators for inspection of the brake pedal push rod retainer ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances and Parts Ordering Information ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6034 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6035 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Inspect all vehicles in stock before delivery. Federal laws requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY INSPECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the Lincoln Commitment Special Handling Procedure. Before contacting Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. REFUNDS See Section 3-59 of the ACESII Manual. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6036 LABOR ALLOWANCES NOTE: Lincoln Commitment Special handling Procedure reimbursement is described in Attachment IV. PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order parts for this recall through normal order processing channels. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES 1999 Expedition and Navigator INSPECTION 1. Inspect brake pedal push rod retainer (yellow clip) to verify that it is in place. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6037 ^ If the retainer is missing install a new retainer. If the retainer is improperly seated, install the retainer in its correct position. NOTE: For vehicles with retainers that are missing or not fully seated call 1-800-325-5621 to report the condition. It is important that Ford track these vehicles. Thank you for your cooperation in this matter. ^ If the retainer is fully seated, no service action is required. Return the vehicle to the customer or saleable stock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6038 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6039 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6040 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > NHTSA98V296000 > Nov > 98 > Recall 98V296000: Master Cylinder Push Rod Retainer Clip Brake Master Cylinder: Recalls Recall 98V296000: Master Cylinder Push Rod Retainer Clip Vehicle Description: Sport utility vehicles. These vehicles may have a missing or partially installed retainer clip that holds the master cylinder pushrod to the brake pedal arm. Increased brake stopping distance can occur, increasing the risk of a crash. Dealers will inspect these vehicles to see if the retainer clip was installed, and repair, if necessary. Owner notification began December 30, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect Technical Service Bulletin # 98S32 Date: 981201 Recall - Brake Pedal Pushrod Retainer Defect SAFETY RECALL 98S32 Certain 1999 Expedition and Lincoln Navigators for inspection of the brake pedal push rod retainer ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances and Parts Ordering Information ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6050 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6051 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Inspect all vehicles in stock before delivery. Federal laws requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY INSPECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the Lincoln Commitment Special Handling Procedure. Before contacting Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. REFUNDS See Section 3-59 of the ACESII Manual. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6052 LABOR ALLOWANCES NOTE: Lincoln Commitment Special handling Procedure reimbursement is described in Attachment IV. PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order parts for this recall through normal order processing channels. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES 1999 Expedition and Navigator INSPECTION 1. Inspect brake pedal push rod retainer (yellow clip) to verify that it is in place. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6053 ^ If the retainer is missing install a new retainer. If the retainer is improperly seated, install the retainer in its correct position. NOTE: For vehicles with retainers that are missing or not fully seated call 1-800-325-5621 to report the condition. It is important that Ford track these vehicles. Thank you for your cooperation in this matter. ^ If the retainer is fully seated, no service action is required. Return the vehicle to the customer or saleable stock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6054 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6055 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 98S32 > Dec > 98 > Recall - Brake Pedal Pushrod Retainer Defect > Page 6056 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > NHTSA98V296000 > Nov > 98 > Recall 98V296000: Master Cylinder Push Rod Retainer Clip Brake Master Cylinder: All Technical Service Bulletins Recall 98V296000: Master Cylinder Push Rod Retainer Clip Vehicle Description: Sport utility vehicles. These vehicles may have a missing or partially installed retainer clip that holds the master cylinder pushrod to the brake pedal arm. Increased brake stopping distance can occur, increasing the risk of a crash. Dealers will inspect these vehicles to see if the retainer clip was installed, and repair, if necessary. Owner notification began December 30, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 6061 Brake Master Cylinder: Specifications TORQUE SPECIFICATIONS Brake Master Cylinder Nuts ....................................................................................................................................................... 22-28 Nm (17-20 ft. lbs.) Front Master Cylinder Brake Line ............................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Line .............................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 6062 Brake Master Cylinder: Description and Operation The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal, and are not indications that the brake master cylinder is in need of repair or replacement: Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the disc brake calipers to compensate for normal brake wear. Add brake fluid as needed. - A momentary or slight ripple of brake fluid inside the brake master cylinder reservoir upon application or release of the brake pedal. - A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder Brake Master Cylinder: Testing and Inspection Brake Master Cylinder Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the symptom chart for abnormal condition diagnosis. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder > Page 6065 Brake Master Cylinder: Testing and Inspection Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder > Page 6066 Brake Master Cylinder: Testing and Inspection Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6067 Brake Master Cylinder: Adjustments Push Rod Adjustment 1. Remove the brake master cylinder. 2. Adjust the power brake booster to brake master cylinder push rod length. 1. Measure the power brake booster to brake master cylinder push rod. 2. If necessary, adjust the screw to the correct length. 3. Install the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the battery ground cable. 2. Disconnect the brake master cylinder fluid level warning switch electrical connector. 3. Use a suitable suction device to drain the brake master cylinder reservoir. Do not reuse the drained fluid. 4. Carefully pry up on the brake master cylinder reservoir to remove. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6070 1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2. Press the brake master cylinder reservoir into the grommets until it snaps. 3. Connect the brake master cylinder fluid level warning switch electrical connector. 4. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6071 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Bench WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. - Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. In-Vehicle Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6072 Bleeding Components WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of He hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6073 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Disassembly and Assembly Disassembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Remove the brake master cylinder. 2. Clean the outside of the brake master cylinder. 3. Remove the brake master cylinder filler cap and drain the remaining brake fluid. Do not reuse the drained fluid. 4. On speed control equipped vehicles, remove the brake pressure switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6074 5. Remove the brake master cylinder fluid control valve). 6. Remove the primary piston assembly. 1. Depress the primary piston, and remove the snap ring. 2. Remove and discard the primary piston assembly. 7. Remove the secondary piston assembly. 1. Plug the rear outlet port and, if necessary, plug the brake pressure switch port. 2. Apply compressed air into the front outlet port, and carefully remove the secondary piston assembly and discard. 8. NOTE: If the brake master cylinder bore is damaged, a new brake master cylinder must be installed. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6075 Assembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Lubricate the new piston assembly seals. Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Do not use oil, as it will destroy the seals. 2. Carefully install the secondary piston assembly. 3. Carefully install the primary piston assembly. 4. Install the snap ring. 1. Depress the primary piston. 2. Install the snap ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6076 5. Install the brake master cylinder fluid control valve. 6. On speed control equipped vehicles, install the brake pressure switch. 7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and install the brake master cylinder filler cap. 8. Bleed the brake master cylinder. 9. Install the brake master cylinder. Removal and Installation Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6077 1. Disconnect the battery ground cable. 2. Disconnect the brake fluid level warning switch electrical connector. 3. On speed control equipped vehicles, disconnect the brake pressure switch electrical connector. 4. NOTE: Use two wrenches on the tube nut at the control valve so as not to loosen the valve. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 6078 5. Remove the brake master cylinder. 1. Remove the two brake master cylinder nuts. 2. Remove the brake master cylinder. Installation 1. Follow the removal procedure in reverse order. - Bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications TORQUE SPECIFICATIONS Cable And Conduit Clip Bolt .................................................................................................................................................. 15-20 Nm (11-14.7 ft. lbs.) Cable Retainer Clip Screw ........................................................................................................................................................... 11-15 Nm (8-11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit Parking Brake Cable: Service and Repair Front Cable and Conduit Removal 1. Remove the parking brake control. 2. Disconnect the front parking brake cable and conduit) from the RH parking brake rear cable and conduit. 3. Remove the front parking brake cable and conduit. 1. Pry the rubber seal from the front floor pan. 2. Compress the retainer and release the front parking brake cable and conduit from the bracket. 3. Remove the front parking brake cable and conduit. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6085 Parking Brake Cable: Service and Repair Rear Cable and Conduit LH Rear Cable and Conduit Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6086 4. Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 1. Compress the parking brake cable clip. 2. Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 5. Remove the screw. 6. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. 7. Unclip the parking brake rear cable and conduit from the parking brake lever. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6087 1. Follow the removal procedure in reverse order. RH Rear Cable and Conduit Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6088 3. Disconnect the front parking brake cable and conduit from the RH parking brake rear cable and conduit. 4. Compress the parking brake cable clip. Remove the RH parking brake rear cable and conduit from the parking brake cable equalizer. 5. Remove the screw. 6. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 6089 7. Unclip the parking brake rear cable and conduit from the parking brake lever. 8. Remove the pushpin located in the crossmember and the RH parking brake rear cable and conduit. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications TORQUE SPECIFICATIONS Parking Brake Control Cowl Panel Bolts ................................................................................................................................ 15-20 Nm (11-14.7 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6093 Parking Brake Control: Service and Repair Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6094 4. Pull to release the three clips and remove the instrument panel steering column cover. 5. Remove the parking brake remote release lever screws. 6. Unhook the remote release lever from the parking brake control. 1. Unhook the cable. 2. Remove the conduit from the clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6095 7. Separate the parking brake control from the cowl panel. 1. Remove the bolts. 2. Disconnect the parking brake signal switch connector. 3. Separate the parking brake control from the cowl panel. 8. Disconnect the front parking brake cable and conduit from the parking brake control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6096 9. Remove the parking brake control. 1. Compress the connector; release the front parking brake cable and conduit. 2. Remove the front parking brake cable and conduit. 3. Remove the parking brake control. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Remote Release To Instrument Panel Bolts .............................................................................................................................................. 2.1-2.9 Nm (18.7-25.8 inch lbs.) Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Special Service Tool(s) Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. Remove the brake disc. 3. Remove the brake shoe retracting spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6103 4. Remove the brake shoe adjusting screw spring. 5. Remove the brake adjuster screw. 6. Remove the brake shoe hold-down spring. 7. Remove the parking brake shoe and linings. 8. Inspect the components for excessive wear or damage and install new components as necessary. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6104 1. Install the parking brake shoe and linings. 2. Install the brake shoe hold-down spring. 3. Install the brake adjuster screw. 4. Install the brake shoe adjusting screw spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6105 5. Install the brake shoe retracting spring. 6. Use the brake adjusting gauge to measure the inside diameter of the drum portion of the brake disc. 7. Use the brake adjusting gauge to set the rear brake shoe and lining diameter. 8. Install the brake disc. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6106 9. Apply tension to the parking brake system. 1. Hold the front parking brake cable and conduit taut. 2. Remove the retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications GENERAL SPECIFICATIONS Booster Push Rod Length .......................................................................................................................................... 24.89-25.27 mm (0.980-0.995 inch) TORQUE SPECIFICATIONS Brake Booster Nuts ............................................................................................................................. ....................................... 22-28 Nm (16-21 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6111 Vacuum Brake Booster: Description and Operation The power brake booster: is a dual diaphragm, vacuum-assisted power brake booster. - reduces brake pedal pressure and travel distance. - is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. - is divided into separate chambers by the diaphragm. - will not operate if vacuum is restricted or if any of the vacuum-related power brake components fail. - is replaced as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6112 Vacuum Brake Booster: Service and Repair Removal 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1. Compress the clamp. 2. Disconnect the power brake booster hose. 3. Remove the stoplight switch self-lock pin. 4. Slide the stoplight switch, booster push rod and the bushing off the brake pedal pin. 5. Remove the bulkhead sound insulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6113 6. Remove the power brake booster. 1. Remove the nuts. 2. Remove the power brake booster. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation The power brake booster check valve: is located on the front of the power brake booster. - is positioned between the power brake booster and the power brake booster hose. - closes when the engine is turned off. - in the closed position, traps engine vacuum in the power brake booster. - retains vacuum to provide several power-assisted brake applications with the engine off. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations The 4WABS relay is located in the battery junction box on the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6124 Electronic Brake Control Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6125 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6126 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the ABS module. 4. Remove the anti-lock brake control module. 1. Remove the screws. 2. Remove the anti-lock brake control module. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6127 1. CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Remote Release To Instrument Panel Bolts .............................................................................................................................................. 2.1-2.9 Nm (18.7-25.8 inch lbs.) Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 9 ft.lb Front ABS Sensor Wire Bracket Bolt 62-80 in.lb Rear Anti-Lock Brake Sensor Bolt 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Removal 1. Disconnect the front anti-lock brake sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front anti-lock brake sensor bolts and the (B) front anti-lock brake sensor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6143 Wheel Speed Sensor: Service and Repair Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1. Disconnect the rear anti-lock brake sensor electrical connector. 2. Remove the bolt. 3. Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removed procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The CPP switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6154 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6155 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6156 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6157 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6158 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6159 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6162 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6163 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6164 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Neutral Safety Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Terminal Nuts ........................................................................................................................ 5-11 N.m (45-97 Lb-In) Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (62-79 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (44-99 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission Starter Relay: Description and Operation Automatic Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The digital transmission range sensor prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission > Page 6174 Starter Relay: Description and Operation Manual Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The clutch pedal position switch prevents starter motor engagement unless the clutch pedal is pressed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 6175 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3 .Disconnect the starter motor solenoid relay switch wires and cables. Disconnect the engine control sensor wiring terminal. - Remove the starter motor solenoid relay switch terminal nuts. - Remove the wiring. 4. Remove the starter motor solenoid relay switch. - Remove the bolts. - Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 6176 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Solenoid Cable Nut .............................................................................................................................. ......................................... 4.5-6.3 N.m (40-56 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6181 Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery cables. 1. Disconnect the battery ground cable. 2. Disconnect the battery to starter relay cable. 2. Remove the two nuts. 3. Remove the (A) battery ground cable body ground nut and the (B) battery ground cable body ground. 4. Remove the bolt. 5. Remove the starter motor solenoid terminal cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6182 6. Disconnect the starter motor connections. 1. Remove the (A) starter motor ground cable nut and disconnect the (B) starter motor ground cable. 2. Remove the (C) solenoid cable nut and disconnect the (D) solenoid cable. 3. Remove the (E) starter motor positive cable nut and disconnect the (F) starter motor positive cable. 7. Remove the cables. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications Alternator Brush: Specifications Generator Brush Screws .............................................................................................................................................................. 2.8-4.0 N.m (2.5-3.5 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Voltage Regulator Screws ............................................................................................................................................................. 2.3-3.4 N.m (20-30 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6191 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6192 Voltage Regulator: Service and Repair REMOVAL NOTE: The voltage regulator is serviceable as an assembly only. 1. Remove the generator. 2. Remove the (A) generator brush holder and the (B) voltage regulator assembly. 1. Remove the screws. 2. Remove the (A) generator brush holder and the (B) voltage regulator assembly. INSTALLATION 1. Install the (A) generator brush holder and (B) voltage regulator assembly. 1. Depress the (C) brushes and insert a (D) wire to hold brushes during installation. 2. Install the (A) generator brush holder and (B) voltage regulator assembly. 3. Install the three screws and remove the (D) wire. 2. Install the generator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The CPP switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: Customer Interest Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6205 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6206 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6207 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6213 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6214 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 6215 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6221 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6222 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6223 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6224 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6225 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6226 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. - Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6229 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6230 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. - Thoroughly clean all drill shavings from the steering column and inspect for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generent combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 6231 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams Neutral Safety Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6243 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6249 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 6255 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 6256 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 6262 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 6263 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation Starter Drive/Bendix: Description and Operation The starter drive: - is operated by the starter solenoid. - engages the flywheel to turn the engine. - has an internal over-running clutch to disengage the starter motor when the engine starts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation > Page 6268 Starter Drive/Bendix: Testing and Inspection 1. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor. 2. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor and flywheel ring gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Terminal Nuts ........................................................................................................................ 5-11 N.m (45-97 Lb-In) Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (62-79 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (44-99 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Automatic Transmission Starter Relay: Description and Operation Automatic Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The digital transmission range sensor prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Automatic Transmission > Page 6274 Starter Relay: Description and Operation Manual Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The clutch pedal position switch prevents starter motor engagement unless the clutch pedal is pressed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Page 6275 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3 .Disconnect the starter motor solenoid relay switch wires and cables. Disconnect the engine control sensor wiring terminal. - Remove the starter motor solenoid relay switch terminal nuts. - Remove the wiring. 4. Remove the starter motor solenoid relay switch. - Remove the bolts. - Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Page 6276 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Terminal Nuts ........................................................................................................................................................... 7-9 N.m (61-79 Lb-In) Solenoid Cable Nut .......................................................................................... ............................................................................. 4.5-6.3 N.m (40-56 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6280 Starter Solenoid: Description and Operation The starter solenoid: - is an electromagnet. - engages the starter drive to the flywheel. - when energized, the contacts close, connecting the battery to the starter motor. This causes the starter motor to turn the starter drive. - is kept in the energized condition by a hold-in winding until the starter switch is released. When the ignition switch is turned to the START position, the starter motor solenoid relay switch is energized, connecting the battery to the starter solenoid. The starter solenoid moves the drive lever and pin to engage the starter drive with the flywheel ring gear and connects the battery to the starter motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6303 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6324 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6325 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6326 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6327 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6328 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6329 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6330 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6331 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Page 6334 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector. ^ Connect the Electronic Pressure Control (EPC) solenoid. ^ Connect the Torque Converter Clutch (TCC). ^ Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6344 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6345 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6346 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6347 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6348 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6349 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6350 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > NHTSA05V388000 > Sep > 05 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6351 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6356 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6357 Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6358 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6376 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6377 Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6378 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6383 Fuse Block: Locations Central Junction Box (Instrument Panel) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6385 The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Fuse Block: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6408 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6412 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6417 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6418 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6419 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6420 Multiple Junction Connector: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6421 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6422 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6423 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6424 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6425 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6426 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6427 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6428 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6430 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6433 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6434 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6435 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6436 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6437 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6438 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6439 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6440 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6441 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6442 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6443 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6444 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6445 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6446 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6447 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6448 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6449 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6450 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6451 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6452 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6453 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6454 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay Power Distribution Relay: Locations Trailer Tow Reversing Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6459 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6460 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6461 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6462 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6464 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6469 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6473 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay Power Distribution Relay: Locations Trailer Tow Reversing Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6478 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6479 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6480 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6481 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6482 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6483 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6489 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6490 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6491 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6492 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6493 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6496 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6497 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6503 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6504 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6505 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6506 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6507 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6508 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6509 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6510 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6511 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6555 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6556 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6557 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6558 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6559 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6560 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6561 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6562 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6568 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6569 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6570 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6571 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6572 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6573 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6574 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6575 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6580 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6581 Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6582 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6600 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6601 Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6602 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6607 Fuse Block: Locations Central Junction Box (Instrument Panel) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6608 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6609 The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 Fuse Block: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6632 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6636 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6641 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6642 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6643 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6644 Multiple Junction Connector: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6645 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6646 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6647 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6648 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6649 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6650 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6651 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6652 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6653 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6656 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6657 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6663 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6664 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6665 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6666 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6667 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6668 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6669 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6670 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6671 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6672 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6673 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6674 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6675 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6676 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6677 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6678 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay Power Distribution Relay: Locations Trailer Tow Reversing Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6683 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6684 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6685 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6686 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6687 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6688 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6693 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6697 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay Power Distribution Relay: Locations Trailer Tow Reversing Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6702 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6703 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6704 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6705 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Reversing Lamp Relay > Page 6706 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6707 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6713 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6714 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6715 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6716 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6717 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6718 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6721 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6727 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6728 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6729 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6730 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6731 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6732 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6733 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6734 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Relay Box > Page 6735 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6741 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6742 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6743 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6744 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6745 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6746 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6747 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6748 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6749 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6750 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6751 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6752 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6753 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6754 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6755 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6756 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6757 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6758 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6759 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6760 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6761 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6762 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6763 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6764 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6765 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6766 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6767 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6768 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6769 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6770 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6771 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6772 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6773 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6774 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6775 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6776 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6777 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6778 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6779 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6780 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6782 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6783 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6784 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6785 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6786 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6787 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6788 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6789 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6790 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6791 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6792 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6793 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6794 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6795 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6796 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6797 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6798 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6799 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6801 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6802 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6803 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6804 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6805 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6806 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6807 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6809 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6811 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6812 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6824 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6825 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6826 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6827 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6828 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6829 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6830 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6831 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6832 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6833 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6834 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6835 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6836 Alignment: Specifications BASE SUSPENSION ALIGNMENT Caster LH ........................................................................................................................................................ ....................................................... 5.1° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.6° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.2° ± 0.7° RH ............................................................................. ................................................................................................................................ -0.2° ± 0.7° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.15° RH ............................................................................. .......................................................................................................................................... 0.15° Total/Split ............................................................................................................................................. ................................................. -0.30° ± 0.25° AIR SUSPENSION ALIGNMENT (TRIM POSITION) Caster LH ........................................................................................................................................................ ....................................................... 5.0° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.5° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.5° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.4° ± 0.4° RH ............................................................................. ................................................................................................................................ -0.4° ± 0.4° Total/Split ............................................................................................................................................. ...................................................... 0.0° ± 0.7° Toe LH ........................................................................................................................................................ ................................................................ 0.10° RH ............................................................................. .......................................................................................................................................... 0.10° Total/Split ............................................................................................................................................. ................................................. -0.20° ± 0.25° RIDE HEIGHT Rear Curb Ride Height: Without Air Suspension .................................................................................................................................................... 218-242 mm (8.6-9.5 inch) With Air Suspension ......................................................................................................................................................... 168-178 mm (6.6-7.0 inch) Vehicle Lean Specifications Max. Allowable Variance, Front ...................................................................................................................................................... 16 mm (5/8 inch) Max. Allowable Variance, Rear ....................................................................................................................................................... 19 mm (3/4 inch) Ride Height Measurement Original Components Base Suspension ............................................................................................................................................................ 102-132 mm (4.02-5.20 inch) Air Suspension Ignition Off (Kneel Position) ................................................................................................................... 60-87 mm (2.36-3.42 inch) Ride Height, Original Components Base Suspension ............................................................................................................................................................ 107-113 mm (4.21-4.44 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Ride Height, New Components Base Suspension ............................................................................................................................................................ 122-128 mm (4.80-5.04 inch) Air Suspension Ignition Off (Kneel Position) ..................................................................................................................... 76-82 mm (3.0-3.23 inch) Rear Vehicle Height [a] ................................................................................................................................................. 144.8-148.8 mm (5.7-5.8 inches) [a] From Bottom Of Frame To Rear Jounce Bumper Bolt Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6837 Alignment: Locations Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6838 Alignment: Description and Operation Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6839 The three basic alignment angles are camber, caster and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications are static settings with the vehicle unloaded. CAMBER Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6840 CASTER Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). TOE Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Wheel Track Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6841 WHEEL TRACK By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking DOGTRACKING Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the upper suspension arm nuts to a point where the joints are snug. 2. NOTE: A pry bar can be used between the front suspension upper arm and the frame pocket to aid in moving the arm. To increase caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension upper arm outboard and move the rear of the front suspension upper arm inboard. 2 To increase camber, move the front suspension upper arm outboard equally. 3. To decrease caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension upper arm inboard and move the rear of the front suspension upper arm outboard. 2 To decrease camber, move the front suspension on upper arm inboard equally. 4. NOTE: Each increment of the notches on the frame pocket represents 0.3°. Set the caster and camber to specifications. If a caster increase of 0.9° is required, move the front of the front suspension upper arm outboard by 3 notches and move the rear of the front suspension upper arm inboard by 3 notches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6844 5. Tighten the upper suspension arm nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6845 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings. 4. Hold the tie rod end while loosening the toe set jam nuts. 5. Rotate the front wheel spindle tie rod adjusting sleeve to desired position. 6. NOTE: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie rod threads must be cleaned and lubricated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6846 Tighten the toe set jam nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module > Page 6853 Steering Control Module: Diagrams With Air Suspension Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations The air suspension compressor relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6858 Compressor/Pump Relay: Description and Operation A solid state relay is used in the air suspension system for compressor control. The relay incorporates a custom power Metal Oxide Semi-Conductor Field Effect Transistor (MOSFET) and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the air suspension control module. The compressor solid state relay is energized by the air suspension control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 6867 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 6868 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 6878 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 6879 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 6884 Suspension Control Module: Description and Operation NOTE: The 4WAS control module is also used for the RAS system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. NOTE: The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performed. A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay) and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing the vehicle and related components. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 6885 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1 Disconnect the electrical connectors. 2 Remove the air suspension control module and bracket assembly. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. NOTE: Ale air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair Steering Column Position Sensor: Service and Repair Removal 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1 Remove the steering column lower bearing spring. 2 Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Page 6894 2. Install the shock absorber electronic steering sensor. 1 Position the shock absorber electronic steering sensor. 2 Install the screws. 3 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 6900 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6901 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the air suspension control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce) to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a usable range of 80 mm (3 inch) compared to total suspension travel of 200-250 mm (8-10 inch) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 inch) of travel at the height sensor. The front height sensor upper socket is attached to the frame bracket at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6902 Ride Height Sensor: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1 Disconnect the electrical connector. 2 Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 6909 Suspension Mode Switch: Description and Operation The air suspension switch supplies power to the air suspension control module. Without the air suspension control module receiving this power, the 4-wheel air suspension system is inoperative and will not react when the vehicle is raised or lowered. If the air suspension is disabled by turning off the air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the RUN position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 6910 Suspension Mode Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 6911 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications TORQUE SPECIFICATIONS Drag Link To Idler Arm Castellated Nut ................................................................................................................................. 77-103 Nm (56-75 ft. lbs.) Drag Link To Sector Shaft Castellated Nut .............................................................................................................................. 77-103 Nm (56-75 ft. lbs.) Drag Link To Inner Tie Rod End Castellated Nut .................................................................................................................................... ............................... 77-103 Nm (56-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 6916 Center Link: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the steering sector shaft arm drag link castellated nuts. 1 Remove the cotter pins. 2 Remove the castellated nuts. 3. On 4x2 vehicles, remove the steering sector shaft arm drag link. - Use the Pitman Arm Puller to separate the steering sector shaft arm drag link from the RH tie rod end, the steering idler arm and bracket, the steering gear sector shaft arm and the LH tie rod end. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 6917 4. On 4x4 vehicles, remove the tie rod ends from the steering sector shaft arm drag link. - Use the remover to separate the steering sector shaft arm drag link from RH and LH tie rod ends. 5. On 4x4 vehicles, remove the steering sector shaft arm drag link. - Use the Pitman Arm Puller to remove the steering sector shaft arm drag link. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 6918 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications TORQUE SPECIFICATIONS Steering Idler Arm And Bracket To Frame Bolt .............................................................................................................................................. 170-230 Nm (125.5-169 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6925 Idler Arm: Service and Repair Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the steering sector shaft arm drag link castellated nuts. 1 Remove the cotter pins. 2 Remove the castellated nut. 3. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6926 4. Remove the steering idler arm and bracket. 1 Remove the bolts. 2 Remove the steering idler arm and bracket. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6927 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications TORQUE SPECIFICATIONS Sector Shaft Arm Drag Link Castellated Nut .......................................................................................................................................................... 77-103 Nm (57-75 ft. lbs.) Sector Shaft Arm Nut ......................................................................................................................................................... 234-316 Nm (173-233 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Special Tools NOTE: If the air is not purged from the power steering system correctly, pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. A whine heard from the power steering pump may be caused by air in the system. The power steering purging procedure must be performed under the following conditions: Prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. - After replacement of any power steering system component (gear, hose, etc.). 1. Remove the power steering fluid reservoir cap. 2. Tightly insert the stopper of the special tool into the power steering fluid reservoir. 3. Start the engine and allow it to idle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6935 4. Using the special tool, apply the maximum vacuum source for a minimum of three minutes with the engine at idle. Maintain the maximum vacuum. 5. Release the vacuum source and remove the special tool. 6. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result loss of power steering assist. Fill the power steering reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent meeting Ford specification MERCON. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6936 7. Using the special tool, apply maximum vacuum. 8. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. Cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum source, and remove the special tool. 10. Add power steering fluid if necessary. Install the power steering fluid reservoir cap. 11. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. Start the engine and cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. 12. Check for power steering fluid leaks at all connections. If the power steering fluid still shows signs of aeration, repeat this procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 6941 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6942 Power Steering Fluid: Specifications Power Steering Fluid Type .................................................................................................................................................... Premium Power Steering Fluid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6943 Power Steering Fluid: Service Precautions CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may result. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications TORQUE SPECIFICATIONS Power Steering Fluid Cooler Bolts ......................................................................................................................................... 9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 6947 Power Steering Fluid Cooler: Service and Repair Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. If equipped, remove the skid plate. 1 Remove the bolts. 2 Remove the skid plate. 3. Remove the lower radiator air deflector. 1 Remove the screws. 2 Remove the push clips. 3 Remove the lower radiator air deflector. 4. Disconnect the power steering fluid cooler hoses. 1 Compress and slide the clamps back. 2 Disconnect the hoses. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 6948 5. Remove the power steering fluid cooler. 1 Remove the bolts. 2 Remove the fluid cooler. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications Power Steering Fluid Reservoir: Mechanical Specifications TORQUE SPECIFICATIONS Reservoir Bracket Bolts To Exhaust Manifold .......................................................................................................................... 68-92 Nm (50-67 ft. lbs.) Upper Reservoir Bracket Bolt ................................................................................................................................................ 9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications > Page 6953 Power Steering Fluid Reservoir: Pressure, Vacuum and Temperature Specifications Air Purge Vacuum ............................................................................................................................... ........................................... 68-85 kPa (20-25 in-Hg) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 6954 Power Steering Fluid Reservoir: Service and Repair Removal 1. Remove the three bolts. Position the power steering pump reservoir aside. 2. Disconnect the hoses. Drain the power steering system. 3. Remove the power steering pump reservoir. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Pressure Hose Fitting ........................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ........................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose Power Steering Line/Hose: Service and Repair Low Pressure Hose Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering low pressure hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering low pressure hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6960 Power Steering Line/Hose: Service and Repair Pressure Hose Special Tool(s) Removal 1. Prepare the vehicle for power steering pressure hose removal. 1 Remove the fan and shroud. 2 Remove the drive belt. 2. Disconnect the power steering pressure hose. Drain the power steering system. 3. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6961 4. Disconnect and remove the power steering pressure hose. Installation 1. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 2. Route the power steering pressure hose in the vehicle. Connect the power steering pressure hose. 3. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Install the power steering pump pulley Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6962 4. Connect the power steering pressure hose 5. Restore the vehicle to operating condition. 1 Install the drive belt. 2 Install the fan and shroud. 3 Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6963 Power Steering Line/Hose: Service and Repair Pump Reservoir Hose Removal 1. Prepare the vehicle for power steering reservoir pump hose removal. 1 Remove the fan and shroud. 2 Remove the drive belt. 2. Remove the three bolts. 3. Disconnect the power steering reservoir pump hose. Drain the power steering system. 4. Remove the nuts and belt deflector. 5. Remove the two bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6964 6. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 7. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 8. Remove the bolt. 9. Lower the vehicle. 10. Position the power steering pump forward. 11. Disconnect and remove the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6965 Installation 1. Route the power steering reservoir pump hose in the vehicle. Connect the power steering reservoir pump hose. 2. Position the power steering pump. 3. Loosely install the bolts. 4. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6966 5. Install the bolt. 6. Connect the EVO power steering control valve actuator electrical connector. 7. Lower the vehicle. 8. Tighten the bolts. 9. Install the belt deflector and nuts. 10. Connect the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6967 11. Position the power steering pump reservoir. Install the three bolts. 12. Restore the vehicle to operating condition. 1 Install the drive belt. 2 Install the fan and shroud. 3 Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Low Pressure Hose > Page 6968 Power Steering Line/Hose: Service and Repair Return Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering return hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering return hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 6969 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pump TORQUE SPECIFICATIONS Power Steering Pump Lower Bolt .............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Power Steering Pump Upper Bolts ............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Power Steering Pump Pulley Press-On Pulley ........................................................................................................................................... Flush to End of Shaft ± 0.25 mm (0.0010 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6974 Power Steering Pump: Pressure, Vacuum and Temperature Specifications GENERAL SPECIFICATIONS Flow ..................................................................................................................................................... ........... 3.0 ± 0.2 gpm @ 50 psi & 2500 pump rpm Minimum Capacity ............................................... ................................................................................................................................ 1.4 gpm @ 750 psi Relief Pressure .............................................................................................................................. .............................................................. 1300-1430 psi Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6975 Power Steering Pump: Application and ID Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6976 Power Steering Pump: Description and Operation NOTE: Earlier builds have four bolts mounting the power steering pump to the engine block. The fourth lower bolt behind the pulley on earlier builds may be discarded upon removal of the power steering pump. The CIII power steering pump has the following features: It is a belt-driven, vane-type, power steering pump. - It is mounted directly to the engine block by three bolts. - The power steering pump is replaced as an assembly. - The identification tag attached to the power steering pump indicates the model number and bar code. Refer to these when pump replacement is required. - The power steering pump uses a quick connect fitting for the power steering pressure hose. - The power steering fluid reservoir is mounted on the LH side of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Removal 1. Prepare the vehicle for power steering pump removal. 1 Remove the fan and shroud. 2 Remove the drive belt. 2. Remove the three bolts. Position the power steering pump reservoir aside. 3. Disconnect the power steering reservoir pump hose. Drain the power steering pump supply line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6979 4. Disconnect the power steering pressure hose. Drain the power steering system. 5. Remove the nuts and belt deflector. 6. Remove the bolts. 7. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle, this can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 8. If equipped, remove the skid plate. 1 Remove the bolts. 2 Remove the skid plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6980 9. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 10. Remove the bolt. 11. Lower the vehicle. 12. Remove the power steering pump. 13. Remove the power steering reservoir pump hose and the power steering pressure hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6981 14. Position the power steering pump in a vise. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. 15. Remove the pump from the vise. Installation 1. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Position the power steering pump in a vise. Install the power steering pump pulley Use the Power Steering Pump Pulley Replacer. - Remove the pump from the vise. 2. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6982 3. Install the power steering reservoir pump hose and the power steering pressure hose. 4. Position the power steering pump in the vehicle. 5. Loosely install the two bolts. 6. Raise and support the vehicle. 7. Install the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6983 8. Connect the EVO power steering control valve actuator electrical connector. 9. If equipped, install the skid plate. 1 Position the skid plate. 2 Install the bolts. 10. Lower the vehicle. 11. Tighten the two bolts. 12. Install the belt deflector and nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6984 13. Connect the power steering pressure hose. 14. Connect the power steering reservoir pump hose. 15. Position the power steering oil reservoir. Install the three bolts. 16. Restore the vehicle to operating condition. 1 Install the drive belt. 2 Install the fan and shroud. 3 Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6985 Power Steering Pump: Service and Repair Power Steering Pump Pulley Special Tool(s) Removal 1. Prepare the vehicle for power steering pump pulley removal. 1 Remove the fan and shroud. 2 Remove the drive belt. 2. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. Installation 1. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Install the power steering pump pulley Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6986 - Use the Power Steering Pump Pulley Replacer. 2. Restore the vehicle to operating condition. 1 Install the drive belt. 2 Install the fan and shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump > Page 6989 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module > Page 6994 Steering Control Module: Diagrams With Air Suspension Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Electronic Variable Orifice Module > Page 7000 Steering Control Module: Diagrams With Air Suspension Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair Steering Column Position Sensor: Service and Repair Removal 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1 Remove the steering column lower bearing spring. 2 Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Page 7008 2. Install the shock absorber electronic steering sensor. 1 Position the shock absorber electronic steering sensor. 2 Install the screws. 3 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7017 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Fry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair > Page 7021 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Specifications Steering Column Cover: Specifications TORQUE SPECIFICATIONS Instrument Panel Steering Column Cover Bolts ............................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair Steering Column Position Sensor: Service and Repair Removal 1. Remove the steering column. 2. Remove the shock absorber electronic steering sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1 Remove the steering column lower bearing spring. 2 Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Page 7028 2. Install the shock absorber electronic steering sensor. 1 Position the shock absorber electronic steering sensor. 2 Install the screws. 3 Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications GENERAL SPECIFICATIONS Ratio .................................................................................................................................................... ........................................................................ 14:1 Worm Bearing Preload ....................................... ................................................................................................................................ 0.9 Nm (8 inch lbs.) Total Meshload Over Worm Bearing Preload ........................................................................................................................... 0.45-1 Nm (4-9 inch lbs.) Steering Gear Meshload .............................................................................................................. ..................................................... 2.0 Nm (18 inch lbs.) Turns Of Steering Wheel (Lock To Lock Linkage Disconnected) ................................................................................................ ................................................................... 3.4 TORQUE SPECIFICATIONS Ball Guide Clamp Bolts .............................................................................................................................................................. 5-7 Nm (45-62 inch lbs.) Meshload Adjuster Lock Nut ..................................................................................................................................................... 26-35 Nm (19-26 ft. lbs.) Power Steering Gear Race Nut ................................................................................................................................................. 75-122 Nm (55-90 ft. lbs.) Sector Shaft Housing Cover Bolts ............................................................................................................................................. 61-75 Nm (45-55 ft. lbs.) Steering Gear Allen Head Race Lock Nut ......................................................................................................................... 1.7-2.8 Nm (15-24.9 inch lbs.) Steering Gear Bolts .............................................................................................................. ...................................................... 68-92 Nm (50-67 ft. lbs.) Valve Housing Bolts ............................. ..................................................................................................................................... 40-60 Nm (30-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7032 Steering Gear: Description and Operation Steering Gear - All Except Motorhome The steering gear has the following features: It is a torsion-bar type hydraulic assisted system. - It reduces road shock and vibration. - It includes a rotary-style hydraulic valve. - It uses a dot matrix ID mark on the gear housing between the valve housing and the sector shaft housing cover. - It may have an optional identification tag mounted to the valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7033 Steering Gear: Adjustments Special Tool(s) MESHLOAD ADJUSTMENT 1. NOTE: The engine should not be running. Turn the steering wheel from right stop to left stop at least once. 2. Remove the driver side air bag. 3. Raise and support the vehicle. 4. Remove the steering sector shaft arm drag link castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7034 5. Using the special tool, separate the steering sector shaft arm drag link. 6. NOTE: The front wheels should not touch the ground. Lower and support the front of the vehicle. 7. NOTE: Measure the torque to turn in the 90° arc just prior to end of travel. Attach a inch lbs. torque wrench to the (A) bolt and measure the steering gear meshload from center. 8. Meshload adjustment is necessary if out of specification. - Adjust meshload as required to obtain center torque greater than end torque. 9. Remove the fan blade assembly and fan shroud to access the sector shaft locknut. 10. Adjust the sector shaft to proper rotating torque. 1 Hold the sector shaft and loosen the meshload adjuster locknut. 2 Adjust the sector shaft screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7035 11. Verify that the static steering wheel turning effort is to specification. - Readjust if necessary. 12. NOTE: Do not overtighten locknut. Tighten the meshload adjuster locknut. 1 Hold the sector shaft screw. 2 Tighten the locknut to specification. 13. Install the steering sector shaft arm drag link castellated nut and cotter pin. 1 Position the steering sector shaft arm drag link. 2 Install the steering sector shaft arm drag link castellated nut. 3 Install a new cotter pin. 14. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 15. Install the fan blade assembly and fan shroud. 16. Install the driver side air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement Steering Gear: Service and Repair Replacement Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the skid plates. 1 Remove the bolts. 2 Remove the skid plate. 3. Slide back the plastic cover from the intermediate steering shaft to the steering gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7038 4. Remove the intermediate shaft pinch bolt and remove the intermediate steering shaft from the steering gear. 5. Remove the steering shaft arm drag link castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. 6. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link. 7. Mark a reference point between the steering gear sector shaft and the steering gear housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7039 8. Remove the steering gear to frame mounting bolts. - Note the location of each bolt during removal. 9. CAUTION: Use care not to damage or bend the power steering cooler tubes. Disconnect the power steering fluid return line. 1 Support the steering gear. 2 Slide back the spring clamp. 3 Disconnect the power steering fluid return line and allow the fluid to drain. 10. Remove the pressure line from the steering gear and remove the steering gear from the vehicle. 11. Secure the steering gear in a vise. Remove the nut and lockwasher. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7040 12. Use the Pitman Arm Puller to remove the steering gear sector shaft arm. - Note the position of the steering gear sector shaft arm. 13. Remove the power steering fluid return line. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7041 1. NOTE: The steering gear sector shaft arm to sector shaft nut must be installed and tightened to specification prior to installation of the steering gear for clearance purposes. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7042 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7043 Steering Gear: Service and Repair Overhaul Disassembly Special Tool(s) (Part 1) NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7044 Special Tool(s) (Part 2) 1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws. 2. Rotate the power steering gear input shaft and control from stop to stop and then center the gear. 3. Remove the steering gear sector shaft housing cover bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7045 4. Tap on the lower end of the steering gear sector shaft. 5. Remove the steering gear sector shaft. 6. Remove the locking nut from the steering gear sector shaft adjustment screw. 7. Remove the sector shaft housing cover. - Hold the steering gear sector shaft. - Turn the housing cover counterclockwise. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7046 8. Remove the valve housing bolts and the identification tag. 9. Remove the valve housing and piston assembly. 10. Remove and discard the gasket. 11. Remove the ball bearings. 1 Remove the bolts. 2 Remove the steering gear ball return guide clamp. 3 Remove the steering gear ball return guide. 4 Rotate the piston over a container to collect the 28 steering gear worm balls. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7047 12. Remove the input shaft valve and housing assembly from the piston. 13. Remove and discard the seal. 14. Install the valve housing in Bench Mounted Holding Fixture and loosen the setscrew. 15. Use Adjuster and Locknut Wrench to remove the race nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7048 16. Remove the power steering gear input shaft and control from the valve housing. 17. Rotate the valve housing with Bench Mounted Holding Fixture. 18. Use Puller to remove the power steering gear input shaft seal dust seal. 19. Remove the input shaft snap ring. 20. Rotate the valve housing with Bench Mounted Holding Fixture and use Input Shaft Bearing/Seal Tool to remove the bearing and power steering gear input shaft seal. 21. Remove the valve housing from Bench Mounted Holding Fixture. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7049 22. Install the steering gear housing in Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore. 23. Remove the spacer. 1 Remove the snap ring. 2 Remove the spacer. 24. NOTE: The steering gear sector shaft bearing is not replaceable. Use Puller to remove the sector shaft seal. Assembly 1. Lubricate the sector shaft seal bore. - Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7050 2. Use Sector Shaft Seal Replacer to install the sector shaft seal. - Lubricate the sector shaft seal, use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 3. Install the spacer. 4. Install the snap ring. 5. NOTE: Place the steering gear sector shaft dust seal on Sector Shaft Seal Replacer so the raised lip is toward the tool. Use Sector Shaft Seal Replacer to install the sector shaft dust seal. Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 6. Remove the steering gear housing from Bench Mounted Holding Fixture. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7051 7. Position the input shaft bearing in the valve housing and use Input Shaft Bearing/Seal Tool Set and a press to seat the bearing. 8. Use Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal. 9. Install the input shaft snap ring. 10. Use Input Shaft Bearing/Seal Tool to install the power steering gear input shaft dust seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7052 11. Mount the valve housing in Bench Mounted Holding Fixture. 12. Install the power steering gear input shaft and control into the valve housing. 13. Position the power steering gear race nut into the valve housing. 14. Use Adjuster and Locknut Wrench to tighten the race nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7053 15. Install the setscrew. 16. Remove the valve housing from Bench Mounted Holding Fixture and position the piston on the worm gear. 17. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which could cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure. Install the steering gear ball return guide on the piston. 18. WARNING: The correct number of balls are required for proper gear operation. Count the balls and insert each carefully. WARNING: To make sure the balls are properly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1 mm (2-3/4 inches) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7054 Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide. 19. Install the steering gear ball return guide clamp. 1 Position the steering gear ball return guide clamp. 2 Install the bolts. 20. Stall a new gasket. 21. Lubricate and install the seal on the piston. - Use Multi-Purpose Grease DOAZ-1958-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESRM1C159-A. 22. NOTE: Make sure to align the oil passages in the steering gear housing. Install the piston assembly into the steering gear housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7055 23. Rotate the teeth so they are on the same plane as the steering gear sector shaft 24. Loosely install the valve housing bolts and the identification tag, if so equipped. 25. Lubricate the O-ring on the sector shaft housing cover. - Use Multi-Purpose Grease DOAZ 19584AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7056 27. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment. Install the sector shaft lock nut. 28. NOTE: Loosely install the sector shaft housing bolts. Install the sector shaft and housing assembly. 29. Tighten the bolts. 30. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 7057 Steering Gear: Tools and Equipment Special Tool Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications TORQUE SPECIFICATIONS Intermediate Shaft Pinch Bolt .................................................................................................................................................... 40-54 Nm (30-40 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications GENERAL SPECIFICATIONS Static Steering Wheel Turning Effort ............................................................................................................................................... 2.0 Nm (18 inch lbs.) Turning Effort ................................................................................................................. ....................................................................... 2.72 Kg (6.0 lbs.) TORQUE SPECIFICATIONS Steering Wheel Bolt ............................................................................................................................. ...................................... 31-44 Nm (23-32 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7064 Steering Wheel: Service and Repair Special Tool(s) Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery cables. 1 Disconnect the battery ground cable and wait at least one minute. 2 Disconnect the battery to starter relay cable and wait one minute for the backup power supply to be depleted. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7065 2. Remove the driver side air bag module. 1 Remove the two screws. 2 Disconnect the air bag sliding contact electrical connector. 3 Disconnect the horn electrical connector. 4 Remove the driver side air bag module. 3. Remove the steering wheel bolt. 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the Differential Side Bearing Puller to remove the steering wheel. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7066 WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Install the steering wheel. 1 Position the steering wheel. 2 Install the bolt. 2. Install the driver side air bag module. 1 Connect the air bag sliding contact electrical connector. 2 Connect the horn electrical connector. 3 Position the driver side air bag module. 4 Install the two screws. 3. Connect the battery cables. 1 Connect the battery to starter relay cable. 2 Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 7067 Special Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures Tie Rod End: Technical Service Bulletins Steering - Tie Rod End Inspection Procedures Article No. 03-15-13 08/04/03 STEERING - TIE ROD END INSPECTION PROCEDURE FORD: 1997-2002 EXPEDITION 1997-2003 F-150 2001-2004 ESCAPE LINCOLN: 1998-2002 NAVIGATOR 2002-2003 BLACKWOOD This article supersedes 03-9-9 to update the vehicle models covered. ISSUE This article is to be used as an updated procedure for inspecting tie rod end wear. ACTION This procedure is designed to supplement the Workshop Manual, as it provides a more detailed tie rod end inspection procedure. SERVICE INFORMATION NOTE FOR ESCAPE VEHICLES, THIS TIE ROD END INSPECTION PROCEDURE SHOULD ONLY BE COMPLETED ON THE OUTER TIE RODS. FOR ESCAPE INNER TIE ROD INSPECTION PROCEDURES, REFER TO WORKSHOP MANUAL SECTION 211-00. Step 1 - Free Play: Check the outer tie rod ends by grasping by hand and push up and down. Check the inner tie rod ends, pushing them front to rear. If any free play is observed in a joint, it is worn and should be replaced. Step 2 - Stud Lash - Free Play: While vehicle is on the ground or on a drive-on hoist, have an assistant rotate the steering wheel rapidly back and forth from 10 o'clock to 2 o'clock to 10 o'clock while observing the inner and outer tie rods. If the outer tie rod ends have any vertical movement or the inner tie rod ends have any horizontal movement, the tie rod end with the observed movement should be replaced. Step 3 - Seal Inspection: Raise the vehicle on a hoist and remove the front wheels. The wheels will need to be turned to the right in order to inspect the passenger side inner tie rod end and to the left to inspect the drivers side inner tie rod end. Inspect all four seals for tears, perforations and wear. If there is any indication of wear or perforations on the seal, that tie rod end should be replaced. Step 4 - Stud Corrosion: For Escape Vehicles - If Squeak is noticed during Step 2, disconnect tie rod from knuckle and articulate stud in socket. If squeak is verified, replace part. While pushing down on seal, at stud end, if corrosion present at contact point at base of stud, replace part. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 7073 For All Other Vehicles Covered In This Article: Using a wrench, rotate the tie rod end so that the front of the seal on the outer tie rod end is expanded (Figure 1). Using a puffy knife or other hard, flat, dull object, lift the bottom of the seal up, exposing the stud (Figure 2). If any water escapes from the seal in the form of bubbles or in a liquid form, that tie rod end should be replaced. Closely examine the stud for signs of corrosion, especially around the interface with the knuckle. A rag might be needed to clean off any grease on the stud that impairs a good visual inspection. If there is any sign of corrosion, that tie rod end should be replaced. Rotate the tie rod end in the opposite direction to expand the inner tie rod seal. Repeat the inspection procedure used on the outer tie rod. Repeat this entire procedure on the other side of the vehicle. If there is sign of corrosion, that tie rod end should be replaced. NOTE IF ANY TIE ROD ENDS ARE REMOVED, INSPECT THE SEAL AND THE STUD AGAIN NOTING ANY DIFFERENCES IN VISUAL PERCEPTIONS FROM WHEN THE PART WAS ON THE VEHICLE. CHECKING THE STUD AFTER REMOVAL HELPS IMPROVE CONSCIOUSNESS OF ISSUES WHEN INSPECTING PARTS ON VEHICLE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-9 WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 7074 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 7075 Tie Rod End: Specifications Outer Tie Rod End Castellated Nut ............................................................................................................................................. 77-103 Nm (56-75 ft. lbs.) Toe Set Jam Nut .................................................................................................... ....................................................................... 77-103 Nm (56-75 ft. lbs.) Drag Link To Inner Tie Rod End ................................................................................................................................................. 77-103 Nm (56-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in, shifting of the vehicle during these operations. Remove the wheel and tire assembly. 2. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 3. Remove the inner tie rod end castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7078 4. On 4x2 vehicles, use the Pitman Arm Puller to separate the tie rod end. 5. On 4x4 vehicles, use the Remover to separate the tie rod end. 6. Remove the tie rod end. 1 Loosen the toe set jam nut. 2 Remove the tie rod end. Count and record rotations. Installation 1. Follow the removal procedure in reverse order. 2. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7079 Tie Rod End: Service and Repair Outer Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Remove the wheel and tire assembly. 2. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 3. Remove the outer tie rod castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7080 4. Use the Pitman Arm Puller to separate the tie rod end. 5. Remove the tie rod end. 1 Loosen the toe set jam nut. 2 Remove the tie rod end. Count and record the rotations. Installation 1. Follow the removal procedure in reverse order. 2. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7081 Tie Rod End: Service and Repair Replacement Removal 1. Remove the outer tie rod end. 2. Remove the front wheel spindle tie rod adjusting sleeve. 1 Loosen the toe set jam nut. 2 Remove the front wheel spindle tie rod adjusting sleeve. Count and record the rotations. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 7082 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7088 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7089 Ball Joint: Specifications Ball Joint, Lower TORQUE SPECIFICATIONS Lower Ball Joint Castle Nut ................................................................................................................................................. 113-153 Nm (83-112 ft. lbs.) GENERAL SPECIFICATIONS Ball Joint Maximum Radial Play ..................................................................................................................................................... 0.794 mm (1/32 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7090 Ball Joint: Specifications Ball Joint, Upper TORQUE SPECIFICATIONS Upper Ball Joint Castle Nut ..................................................................................................................................................... 77-103 Nm (57-76 ft. lbs.) GENERAL SPECIFICATIONS Maximum Radial Play .......................................................................................................................... ........................................... 0.794 mm (1/32 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7093 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7094 Ball Joint: Testing and Inspection Ball Joint, Lower UPPER/LOWER ARM BALL JOINTS-FRONT SUSPENSION WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. NOTE: Prior to performing any inspection on 4x2 vehicles of the front suspension lower arm ball joints or front suspension upper ball joints, adjust the front wheel bearings. NOTE: Refer to the illustration for Steps 1 and 2. 1. Raise the vehicle and place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7095 Ball Joint: Testing and Inspection Ball Joint, Upper UPPER/LOWER ARM BALL JOINTS-FRONT SUSPENSION WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. NOTE: Prior to performing any inspection on 4x2 vehicles of the front suspension lower arm ball joints or front suspension upper ball joints, adjust the front wheel bearings. NOTE: Refer to the illustration for Steps 1 and 2. 1. Raise the vehicle and place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications TORQUE SPECIFICATIONS Front Suspension Lower Arm Nuts .......................................................................................................................................................... 164-200 Nm (121-147 ft. lbs.) Upper Arm Nuts ............................................................................................................................................................. 113-153 Nm (83-113 ft. lbs.) Rear Suspension Lower Arm Assembly To Axle Bolt .............................................................................................................................. 128-172 Nm (94-127 ft. lbs.) Lower Arm Assembly To Frame Bolt ............................................................................................................................ 128-172 Nm (94-127 ft. lbs.) Upper Arm Assembly To Frame Bolt ............................................................................................................................ 128-172 Nm (94-127 ft. lbs.) Upper Arm Assembly To Axle Bolt ............................................................................................................................... 128-172 Nm (94-127 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm: Service and Repair Lower Removal 1. Remove the wheel hub. 2. Make preliminary adjustment references. 1 Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2 Measure and record the length. 3. Relieve the torsion bar tension. 1 Remove the torsion bar adjuster bolt. 2 Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. 4 Remove the torsion bar adjuster nut. 5 Remove the Torsion Bar Tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7101 6 Remove the torsion bar adjuster. 4. Remove the stabilizer bar link nut from the front suspension lower arm. 5. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. 6. Remove the lower ball joint castle nut. 1 Remove and discard the cotter pin. 2 Remove the lower ball joint castle nut. 7. Using the Pitman Arm Puller, separate the front suspension lower arm from the front wheel knuckle. - Separate the front suspension lower arm from the front wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7102 8. Remove the front suspension lower arm. 1 Remove the two front suspension lower arm nuts. 2 Remove the two front suspension lower arm bolts. 3 Remove the front suspension lower arm and torsion bar as an assembly. 9. Separate the front suspension lower arm from the torsion bar. Installation 1. Install the front suspension lower arm. 1 Attach the front suspension lower arm to the torsion bar. 2 Install the front suspension lower arm and torsion bar as an assembly. 3 Install the front suspension lower arm bolts and nuts. 2. Install the front suspension arm lower ball joint castle nun 1 Position the front wheel knuckle. 2 Install the front suspension arm lower ball joint castle nut. 3 Install a new cotter pin. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7103 3. Install the front stabilizer bar link to the front suspension lower arm. 4. Install the front shock absorber lower bolt and nut to the front suspension lower arm. 5. Load the torsion bar. 1 Install the torsion bar adjuster. Turn the torsion bar adjuster until the reference marks align. 2 Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3 Tighten the Torsion Bar Tool to load the torsion bar. 4 Install the torsion bar adjuster nut. 5 Install the torsion bar adjuster bolt. 6 Remove Torsion Bar Tool. 6. Install the wheel hub. 7. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7104 Control Arm: Service and Repair Upper Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Remove the wheel and tire assembly. 3. Support the front suspension lower arm. - Position a jack under the front suspension lower arm. 4. Mark the position of the camber adjustment cam. 5. Safely reposition the anti-lock sensor wire. 1 Remove the bolt. 2 Safely reposition the anti-lock sensor wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7105 6. Remove the upper ball joint castle nut. 1 Remove and discard the cotter pin. 2 Remove the upper ball joint castle nut. 7. Use the Pitman Arm Puller to separate the front suspension upper arm from the front wheel knuckle. 8. NOTE: Mark the position of the camber adjustment cam. Remove the front suspension upper arm. 1 Remove the front suspension upper arm nuts. 2 Remove the front suspension upper arm pivot bolts. 3 Remove the front suspension upper arm. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7106 1. NOTE: Align the marks made during removal. Install the front suspension upper arm. 1 Position the front suspension upper arm. 2 Install the front suspension upper arm bolts. 3 Install the front suspension upper arm nuts. 2. Install the front suspension arm upper ball joint castle nut. 1 Position the front wheel knuckle. 2 Install the upper ball joint castle nut. 3 Install a new cotter pin. 3. Position the anti-lock sensor wire. - Install the front brake anti-lock sensor wire bracket bolt. 4. Remove the jack. 5. WARNING: the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the lug nuts are loosened. WARNING: Failure to retighten lug nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Install the tire and wheel assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7107 1 Position the tire and wheel assembly. 2 Install the lug nuts. 3 Tighten the lug nuts in the sequence indicated. 4 Install the center cap. 6. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 7. Check the front end alignment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Page 7108 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Removal 1. Remove the wheel hub. 2. Make preliminary adjustment references. 1 Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2 Measure and record the length. 3. Relieve the torsion bar tension. 1 Remove the torsion bar adjuster bolt. 2 Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. 4 Remove the torsion bar adjuster nut. 5 Remove the Torsion Bar Tool. 6 Remove the torsion bar adjuster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7112 4. Safely reposition the anti-lock sensor wire. 1 Remove the bolt. 2 Safely reposition the anti-lock sensor wire. 5. Remove the tie rod end castle nut. 1 Remove and discard the cotter pin. 2 Remove the tie rod end castle nut. 6. Using the Pitman Arm Puller, separate the tie rod end. - Separate the tie rod end from the front wheel knuckle. 7. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7113 8. Remove the upper ball joint castle nut. 1 Remove and discard the cotter pin. 2 Remove the upper ball joint castle nut. 9. Using the Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. 10. Remove the lower ball joint castle nut. 1 Remove and discard the cotter pin. 2 Remove the lower ball joint castle nut. 11. Using the Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle. 12. CAUTION: Do not allow the front wheel driveshaft and joint to hang unsupported. Suspend the front wheel driveshaft and joint with wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7114 Remove the front wheel knuckle. Installation 1. Install the front suspension arm lower ball joint castle nut. 1 Position the front wheel knuckle. 2 Install the front suspension arm lower ball joint castle nut. 3 Install a new cotter pin. 2. Install the front suspension arm upper ball joint castle nut. 1 Position the front wheel knuckle. 2 Install the front suspension arm upper ball joint castle nut. 3 Install a new cotter pin. 3. Install the front shock absorber lower bolt and nut to the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7115 4. Install the tie rod end castle nut. 1 Position the tie rod end. 2 Install the tie rod end castle nut. 3 Install a new cotter pin. 5. Position the anti-lock sensor wire. - Install the front brake anti-lock sensor wire bracket bolt. 6. Load the torsion bar. 1 Install the torsion bar adjuster. Turn the torsion bar adjuster until the reference marks align. 2 Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3 Tighten the Torsion Bar Tool to load the torsion bar. 4 Install the torsion bar adjuster nut. 5 Install the torsion bar adjuster bolt. 6 Remove the Torsion Bar Tool. 7. Install the wheel hub. 8. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7116 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations The air suspension compressor relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7121 Compressor/Pump Relay: Description and Operation A solid state relay is used in the air suspension system for compressor control. The relay incorporates a custom power Metal Oxide Semi-Conductor Field Effect Transistor (MOSFET) and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the air suspension control module. The compressor solid state relay is energized by the air suspension control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7130 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7131 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7141 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7142 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7147 Suspension Control Module: Description and Operation NOTE: The 4WAS control module is also used for the RAS system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. NOTE: The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performed. A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay) and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing the vehicle and related components. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7148 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1 Disconnect the electrical connectors. 2 Remove the air suspension control module and bracket assembly. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. NOTE: Ale air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 7154 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 7155 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the air suspension control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce) to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a usable range of 80 mm (3 inch) compared to total suspension travel of 200-250 mm (8-10 inch) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 inch) of travel at the height sensor. The front height sensor upper socket is attached to the frame bracket at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 7156 Ride Height Sensor: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1 Disconnect the electrical connector. 2 Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Description and Operation Steering Angle Sensor: Description and Operation The steering sensor provides the steering rate and position to the air suspension control module through two signals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7163 Suspension Mode Switch: Description and Operation The air suspension switch supplies power to the air suspension control module. Without the air suspension control module receiving this power, the 4-wheel air suspension system is inoperative and will not react when the vehicle is raised or lowered. If the air suspension is disabled by turning off the air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the RUN position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7164 Suspension Mode Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 7165 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications TORQUE SPECIFICATIONS Front Stabilizer Bar Link Bolt And Nut ........................................................................................................................................ 21-29 Nm (16-21 ft. lbs.) Rear Stabilizer Bar Link To Frame Bolt ..................................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Stabilizer Bar Link To Stabilizer Bar Nut .......................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Dryer: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7175 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7176 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Page 7177 Air Dryer: Specifications TORQUE SPECIFICATIONS Air Compressor Drier Hold Down Screw ................................................................................................................................... 2-3 Nm (18-27 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Page 7178 Air Dryer: Service and Repair Removal 1. Remove the air compressor. 2. Remove the air compressor drier. 1 Remove the screw. 2 Rotate 90° to unlock then remove the air compressor drier. Installation 1. NOTE: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. NOTE: Ride height adjustments must be performed after the air compressor/drier is installed. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Line: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7183 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7184 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Page 7185 Air Line: Description and Operation There are six nylon air lines with quick connect air fittings in the vehicle that connect the air compressor, solenoids, air shocks and air springs. One line connects the output of the compressor assembly to the front fill solenoid and the other two lines connect the output of the compressor assembly to the rear fill solenoid. Another line connects the output of the rear fill solenoid to both rear air springs. The fifth air line in the front connects the output of the front fill solenoid to both the right front air shock and the front gate solenoid. The last air line connects the output of the gate solenoid to the left air shock. The air lines cannot be spliced or repaired if the air lines have been cut or ruptured. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Page 7186 Air Line: Service and Repair NOTE: A soapy water solution can be applied to the air lines to verify the location of air leaks. 1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight cut. Trim back the outer covering of the air line 16-20 mm (0.63-0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely with electrical tape. 2. If multiple leaks are detected, replace the entire air line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Specifications Air Spring: Specifications TORQUE SPECIFICATIONS Four Wheel Air Suspension Air Shock Lower Bolt ........................................................................................................................................................ 76-103 Nm (56-76 ft. lbs.) Air Shock Lower Bolt .......................................................................................................................................................... 50-60 Nm (37-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Description and Operation > Rear Air Spring Air Spring: Description and Operation Rear Air Spring The 4WAS vehicles use air springs in the rear. The air springs provide a varying spring rate proportional to the system's air pressure and volume. The air suspension system regulates the air pressure in each air spring by compressing and venting the system's air. Increasing air pressure (compressing) raises the vehicle; decreasing air pressure (venting) lowers the vehicle. Vehicle height is maintained by the addition and removal of air in each air spring through an air spring solenoid installed in the upper spring cap and energized through the air suspension control module command. The air springs replace the conventional coil springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Description and Operation > Rear Air Spring > Page 7192 Air Spring: Description and Operation Front Air Shock Absorbers Adjustable air shock absorbers are used for the 4WAS system vehicles. Enclosed in each shock absorber is an air spring. Replace a faulty shock absorber as a unit. The air spring integrated into each air shock is capable of independently raising and lowering each corner of the vehicle based upon the pressure and volume of air supplied. The air suspension system regulates the pressure in each air shock by compressing and venting system air. Increasing air pressure (compressing) raises the vehicle and increases the total spring rate (spring effect of the air shock plus the front torsion bar) of the wheel being modified. Conversely, decreasing air pressure (venting) lowers the vehicle and effective spring rate. Vehicle height is then maintained by the addition and removal of air in each air shock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front Air Spring: Service and Repair Front Removal NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Raise and support the vehicle. 3. On LH air shock removal only, disconnect the top of the front height sensor from the upper frame bracket. 4. Remove the air shock lower nut and bolt. 5. Disconnect the air spring solenoid air line. - Compress the quick connect locking ring and pull out the air line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7195 6. Remove the air shock upper nut, grommet, and the air shock. Installation 1. NOTE: After installing the air shock, it is necessary to inflate the air suspension system. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7196 Air Spring: Service and Repair Rear Removal WARNING: Before repairing or installing any air suspension component(s), turn off the air suspension switch or disconnect the battery ground cable to prevent vehicle damage or personal injury. WARNING: Do not attempt to install or inflate any air spring that has become unfolded to prevent vehicle damage or personal injury. WARNING: Failure to observe the procedures may result in a sudden failure of the suspension system WARNING: Any air spring which is unfolded must be refolded prior to being installed in a vehicle. WARNING: The air spring refolding procedure should not be used for an air spring which has never supported the vehicle's weight while in the correctly folded position. WARNING: Vehicles with an incorrectly folded air spring(s) found after the vehicle has been driven, must have a new air spring installed. WARNING: Do not attempt to inflate any air spring which has collapsed while deflated from the rebound hanging position to the jounce stop. WARNING: When installing a new air spring, care must be taken to not apply a load to the suspension until the air springs have been inflated using the air spring fill procedure. WARNING: After inflating an air spring in the hanging position, it must be inspected for proper shape. NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the rear air spring retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7197 5. Lift the bottom of the air spring off the rear axle. 6. Disconnect the air line from the air spring. - Compress the quick connect locking ring and pull out the air line. 7. Disconnect the air spring solenoid electrical connector and remove the air spring. Installation 1. NOTE: When installing the rear air spring, it is necessary to inflate the air suspension system. Connect the solenoid valve electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7198 2. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Connect the air line into the solenoid valve line fitting. 3. Position the air spring into place and install the retaining clip at the top of the air spring. 4. Visually inspect each air spring to ensure the correct profile has been obtained and the air spring is secured to the axle housing. There should be no evidence of buckling or folding of the air springs. 5. Lower the vehicle. 6. Inflate the air suspension system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7199 Air Spring: Service and Repair Air Spring Filling or Refolding AIR SPRING FILL - REFOLD WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. CAUTION: Do not clamp any portion of the air spring piston. 1. Place air spring on flat surface. 2. Remove air spring solenoid to expand collapsed air bag. 3. Push membrane down over piston to correct height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 7200 4. Install air spring solenoid to help maintain correct height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: Customer Interest Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises Compressor/Pump: Customer Interest Air Suspension - Underhood Buzzing Noises Article No. 99-2-2 02/08/99 NOISE - "BUZZING" - UNDERHOOD WHEN AIR SUSPENSION IS IN OPERATION LIGHT TRUCK: 1997-99 EXPEDITION, F-25O LD 1998-99 NAVIGATOR This TSB article is being republished in its entirety to add 1998-99 model year vehicles. ISSUE An underhood "buzzing" noise may be heard during air suspension operation. This may be caused by: ^ the air pump lines being routed too close to the front end sheet metal ^ the wheelhouse inner may be sensitive to vibration input of air suspension compressor ACTION Wrap the air lines with foam tape and place mastic applique on sheet metal under air suspension compressor. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE FOAM TAPE MUST BE PLACED ON THE AIR LINES IN A LOCATION THAT WILL PREVENT THE AIR LINES FROM CONTACTING ANY SHEET METAL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7213 1. Wrap the air lines with 12.7x101.6 mm (1/2x4") Foam Tape (Rotunda Squeak and Rattle Repair Kit PVC Foam Tape 164-R4901, or obtained locally) at the locations shown in Figure 1. Expedition/Navigator 4X2 and F-250 will need to be wrapped at A and B in Figure 1. Expedition/Navigator 4X4 will require tape at A, B, C, and D in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7214 2. If no groundouts are found, remove air compressor and place Mastic Appliques (XL1Z-3C244-AA and XL1Z-3C245-AA) on sheet metal under air suspension compressor at A and B in Figure 2. Place appliques as follows: a. Accurately place mastic onto sheet metal in a location that will not allow the cutouts for the mounting bolt to interfere with the mounting bracket. The air suspension compressor mounting bracket and the washer bottle reservoir should have complete contact with the sheet metal, and not the mastic, at the body mounting points. CAUTION BE SURE TO WEAR PROTECTIVE GLOVES WHEN CONFORMING THE MASTIC TO PREVENT FINGER BURNS. b. Using a heat gun, uniformly heat the mastic and apply pressure to form the mastic to the sheet metal surface. PART NUMBER PART NAME (Obtain Locally) 12.7x101.6 mm (1/2x4") Foam Tape XL1Z-3C244-AA Mastic Applique (1 Of 2) XL1z-3C245-AA Mastic Applique (2 Of 2) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-13 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7215 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990202A Apply Foam Tape To 0.5 Hr. Contact Areas - 4X2 And 4X4 Models 990202B Apply Mastic Applique 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 3B484 43 OASIS CODES: 304000, 702000, 702100, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: All Technical Service Bulletins Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7225 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7226 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises Compressor/Pump: All Technical Service Bulletins Air Suspension - Underhood Buzzing Noises Article No. 99-2-2 02/08/99 NOISE - "BUZZING" - UNDERHOOD WHEN AIR SUSPENSION IS IN OPERATION LIGHT TRUCK: 1997-99 EXPEDITION, F-25O LD 1998-99 NAVIGATOR This TSB article is being republished in its entirety to add 1998-99 model year vehicles. ISSUE An underhood "buzzing" noise may be heard during air suspension operation. This may be caused by: ^ the air pump lines being routed too close to the front end sheet metal ^ the wheelhouse inner may be sensitive to vibration input of air suspension compressor ACTION Wrap the air lines with foam tape and place mastic applique on sheet metal under air suspension compressor. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE FOAM TAPE MUST BE PLACED ON THE AIR LINES IN A LOCATION THAT WILL PREVENT THE AIR LINES FROM CONTACTING ANY SHEET METAL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7231 1. Wrap the air lines with 12.7x101.6 mm (1/2x4") Foam Tape (Rotunda Squeak and Rattle Repair Kit PVC Foam Tape 164-R4901, or obtained locally) at the locations shown in Figure 1. Expedition/Navigator 4X2 and F-250 will need to be wrapped at A and B in Figure 1. Expedition/Navigator 4X4 will require tape at A, B, C, and D in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7232 2. If no groundouts are found, remove air compressor and place Mastic Appliques (XL1Z-3C244-AA and XL1Z-3C245-AA) on sheet metal under air suspension compressor at A and B in Figure 2. Place appliques as follows: a. Accurately place mastic onto sheet metal in a location that will not allow the cutouts for the mounting bolt to interfere with the mounting bracket. The air suspension compressor mounting bracket and the washer bottle reservoir should have complete contact with the sheet metal, and not the mastic, at the body mounting points. CAUTION BE SURE TO WEAR PROTECTIVE GLOVES WHEN CONFORMING THE MASTIC TO PREVENT FINGER BURNS. b. Using a heat gun, uniformly heat the mastic and apply pressure to form the mastic to the sheet metal surface. PART NUMBER PART NAME (Obtain Locally) 12.7x101.6 mm (1/2x4") Foam Tape XL1Z-3C244-AA Mastic Applique (1 Of 2) XL1z-3C245-AA Mastic Applique (2 Of 2) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-13 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 7233 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990202A Apply Foam Tape To 0.5 Hr. Contact Areas - 4X2 And 4X4 Models 990202B Apply Mastic Applique 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 3B484 43 OASIS CODES: 304000, 702000, 702100, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7239 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7240 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7241 Compressor/Pump: Specifications TORQUE SPECIFICATIONS Air Compressor Bracket Bolts ............................................................................................................................................ 7.6-10.4 Nm (68-88 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7242 Compressor/Pump: Description and Operation The air compressor: - Is not interchangeable with the Rear Air Suspension (RAS) air compressor. - Consists of the compressor and vent solenoid; neither are replaceable as individual items. - Is a single cylinder electric motor driven unit that provides pressurized air as required. - Is powered by a solid state relay, which is controlled by the air suspension control module. - Passes pressurized air through the compressor air drier that contains silica gel (a drying agent). Moisture is then removed from the compressor air drier when vented air passes out of the system during vent operation. - The drier may be replaced separately. - The drier has dual ports and is not interchangeable with the RAS drier. The vent solenoid: - Allows air to escape from the system during venting actions. - Is part of the air compressor cylinder head. - Shares a common electrical connector with the air compressor motor. - Is enclosed in the cylinder head casting, which forms an integral valve housing that allows the valve tip to enter the pressurized side of the system. - Has an O-ring seal that prevents air leakage past the valve tip. - Opens when the air suspension control module determines lowering is required. - Provides an escape route for pressurized air when system pressures exceed safe operating levels. - Has a 1792 kPa (260 psi) internal relief valve. - Is installed with the air compressor as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7243 Compressor/Pump: Service and Repair Removal 1. WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Remove the windshield washer pump and reservoir. 4. Disconnect the air lines from the air compressor 1 Compress the quick connect locking rings and hold firmly while pulling out on the air lines. 2 Disconnect the air lines. 5. Disconnect the air compressor electrical connector. 6. Remove the air compressor bracket bolts and remove the air compressor and drier assembly. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7244 1. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. NOTE: After installing the air compressor it is necessary to inflate the air suspension system. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations The air suspension compressor relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7248 Compressor/Pump Relay: Description and Operation A solid state relay is used in the air suspension system for compressor control. The relay incorporates a custom power Metal Oxide Semi-Conductor Field Effect Transistor (MOSFET) and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the air suspension control module. The compressor solid state relay is energized by the air suspension control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Level Control Solenoid Valve: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7253 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7254 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve Level Control Solenoid Valve: Description and Operation Electronic Level Control Solenoid Valve WARNING: Never rotate an air spring solenoid valve to the release slot in the end cap fitting until all pressurized air has escaped from the spring to prevent damage or injury. The air spring solenoid: Allows air to enter and exit the air spring during leveling operations. - Is electrically operated and controlled by the air suspension control module. - Is only replaced as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 7257 Level Control Solenoid Valve: Description and Operation Exhaust Solenoid (Level Control) The Pressure Relief Valve (PRV) protects the rear air suspension components by venting the system to a specific pressure in the case of a system malfunction. The system will decrease the pressure to an acceptable level to maintain vehicle height. In the normal operation mode with normal system pressure, the PRV is constantly closed and does not have any effect on the system performance or fiction. The PRV is replaceable without any air lines. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 7258 Level Control Solenoid Valve: Description and Operation Inflator Solenoid, Level Control Front Fill Solenoid The front fill solenoid connects the output of the compressor assembly to the two front air shocks. When energized along with the front gate solenoid, air pressure to the front suspension can be modified affecting its height relative to the body. Front Gate Solenoid The front gate solenoid provides pneumatic isolation of the left and right sides of the vehicle. The separation is necessary to eliminate the transfer of air from the left to the right front air shocks during roll conditions. When the front fill solenoid and front gate solenoid are off (closed), the left and right air shocks are separated, allowing a pressure differential to be generated. In a turn, the increased pressure in the two outermost air shocks raises the two outer wheel spring rates, decreasing vehicle roll. Conversely, opening (energizing) the gate solenoid on smooth driving surfaces connects the left and right air shocks. This forces left and right side air pressures to be the same. Also, allowing the transfer of air reduces the resistance to vertical wheel movement, resulting in a softer ride. Rear Fill Solenoid The rear fill solenoid connects the output of the compressor assembly to the two rear air springs. When energized along with the two rear solenoids, air pressure to the rear suspension can be modified, affecting its height relative to the body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional Level Control Solenoid Valve: Service and Repair Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. Remove the air spring assembly. 2. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing the air spring solenoid from the air spring assembly. Remove the air spring solenoid clip. 3. Twist the air spring solenoid and remove. Installation 1. NOTE: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 7261 Level Control Solenoid Valve: Service and Repair Inline Removal NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. NOTE: Front fill solenoid shown, front gate solenoid and rear fill solenoid similar. Disconnect the electrical connector. 5. Disconnect the solenoid valve air lines. - Compress the red quick connect locking rings and pull out the air lines. 6. NOTE: Front fill solenoid shown, front gate solenoid and rear fill solenoid similar. Remove the solenoid from the frame. Installation 1. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 7262 NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 7263 Level Control Solenoid Valve: Service and Repair Non-Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. NOTE: The air spring solenoid has a two-stage pressure relief fitting similar to a radiator cap. 1. Raise and support the vehicle. 2. Disconnect the air spring solenoid electrical connector. 3. Disconnect the air spring solenoid air line. - Compress the quick connect locking ring and pull out the air line. 4. CAUTION: Remove any dirt or other debris from the air spring prior to removing the air spring solenoid frond the air spring. Remove the air spring solenoid clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 7264 5. Rotate the air spring solenoid out of the air spring to the first detent to release the air from the air spring. 6. Remove the air spring retainer. 7. Lift the bottom of the air spring from the rear axle and remove the air spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Functional > Page 7265 8. Twist the air spring solenoid and remove. Installation NOTE: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A NOTE: Be sure the new air spring solenoid is fully seated into both stages of the air spring. NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications Ride Height Sensor: Electrical Specifications GENERAL SPECIFICATIONS Rear Height Sensor Voltage ................................................................................................................ .................................................... 2.66 ± 0.02 volts Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Electrical Specifications > Page 7270 Ride Height Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Ball Stud Nut ........................................................................................................................................ .......................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 7271 Ride Height Sensor: Description and Operation Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the air suspension control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce) to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a usable range of 80 mm (3 inch) compared to total suspension travel of 200-250 mm (8-10 inch) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 inch) of travel at the height sensor. The front height sensor upper socket is attached to the frame bracket at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is raised above trim under normal driving conditions, this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 7272 Ride Height Sensor: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1 Disconnect the electrical connector. 2 Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7281 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7282 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7292 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7293 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7298 Suspension Control Module: Description and Operation NOTE: The 4WAS control module is also used for the RAS system. The internal processor recognizes external circuitry to determine if it is installed in a 4WAS or a RAS system. NOTE: The air suspension control module is calibrated with information from the air suspension height sensors. A new or swapped air suspension control module requires the ride height adjustment calibration process to be performed. A microcontroller-based electronic air suspension control module controls the air compressor motor (through a solid state relay) and all system solenoids. The air suspension control module also provides power to front and rear height sensors. The air suspension control module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals and the Brake Pedal Position (BPP) switch. The air suspension control module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing the vehicle and related components. The air suspension control module is interchangeable between the RAS and 4WAS system. The air suspension control module monitors and controls the system through a 32-pin two-way connector. The air suspension control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the air suspension control module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7299 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1 Disconnect the electrical connectors. 2 Remove the air suspension control module and bracket assembly. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. NOTE: Ale air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Bracket Mounting Bolt ................................................................................................................................................... 10.2-13.8 Nm (92-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7303 Suspension Mode Switch: Description and Operation The air suspension switch supplies power to the air suspension control module. Without the air suspension control module receiving this power, the 4-wheel air suspension system is inoperative and will not react when the vehicle is raised or lowered. If the air suspension is disabled by turning off the air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the RUN position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7304 Suspension Mode Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 7305 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal Suspension Spring ( Coil / Leaf ): Service and Repair Removal 1. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Remove the wheel and tire assembly. 3. Remove the driveshaft. 4. Disconnect the rear Brake Anti-Lock Sensor (ABS) electrical connector. 5. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7310 2 Insert a suitable retainer into the parking brake control. 6. Disconnect the rear parking brake cable and conduit from the rear axle. 1 Remove the rear parking brake cable and conduit from the rear axle bracket assembly. 2 Remorse the cable from the caliper. Repeat for the other side. 7. Position the disc brake caliper aside. 1 Remove the bolts. 2 Secure the caliper aside with wire. Repeat for the other side. 8. Disconnect the axle vent tube. 9. Disconnect the stabilizer bar from the rear axle. 1 Remove the bolts from each stabilizer bar retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7311 2 Remove the retainers. 10. Use the Hi-Lift Jack to support the rear axle. 11. Remove the lower shock absorber nut and bolt. - Repeat for the other side. 12. Remove the rear axle-to-trackbar assembly bolt. 13. Remove the rear suspension lower arm assembly-to-axle bolt. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7312 14. Remove the rear suspension upper arm assembly-to-rear axle bolt. - Repeat for the other side. 15. Lower the rear axle and remove the coil spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7313 Suspension Spring ( Coil / Leaf ): Service and Repair Installation NOTE: Do not tighten any nuts or bolts until the rear suspension is raised so that the rear suspension lower arms are parallel to the ground. Once in position, tighten all the nuts and bolts to specification. 1. Install the rear coil spring. 2. Position the rear suspension upper arm assemblies to the axle and install the bolts. 3. Position the rear suspension lower arm assemblies to the axle and install the bolts. 4. Position the trackbar assembly to the axle and install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7314 5. Position the shock absorbers to the axle and install the bolts. 6. Position the stabilizer bar to the axle and install the stabilizer bar retainers and bolts. 7. Position the disc brake caliper. 1 Position caliper. 2 Install the bolts. 8. Connect the parking brake cables and conduit to the axle. 1 Install the cable and conduit to the lever. 2 Install the cable and conduit to the rear axle bracket assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 7315 9. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug nuts and lower the vehicle. 3 Tighten the lug nuts in sequence. 4 Install the wheel cover. 10. Remove the pin from the parking brake control assembly. 11. Connect the rear Brake Anti-Lock Sensor (ABS) electrical connector. 12. Connect the axle vent tube. 13. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7316 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications TORQUE SPECIFICATIONS Front Shock Lower Bolt And Nut ................................................................................................................................................ 77-103 Nm (57-76 ft. lbs.) Shock Upper Nut ................................................................................................... ............................................................... 30-40 Nm (22-29 ft. lbs.) Rear Shock Absorber To Axle Nut ............................................................................................................................................. 86-114 Nm (63-84 ft. lbs.) Shock Absorber To Frame Nut .......................................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Suspension Strut / Shock Absorber: Initial Inspection and Diagnostic Overview CAUTION: The low pressure gas shock absorbers are charged with nitrogen gas to 931 kPa (135 psi) for 1-3/16 inch bore, and 1034 kPa (150 psi) for 1-3/8 inch bore. Do not attempt to open, puncture, or apply heat to the shock absorbers. All vehicles are equipped with low pressure gas-filled hydraulic shock absorbers of the direct acting type. They are non-adjustable and non-refillable. They cannot be serviced as cartridges and must be serviced as shock assemblies. Before replacing a shock absorber, check the action of the shock absorbers as follows. 1. Check all tires for proper inflation pressure. 2. Check tire condition to confirm proper front end alignment, tire balance and overall tire condition such as separation or bulges. 3. Check the vehicle for optional suspension equipment such as heavy-duty handling or trailer tow suspensions. These suspensions will have a firmer feeling ride than standard suspensions. 4. Check the vehicle attitude for evidence of possible overload or sagging. Many times, front springs and front shock absorbers are replaced in an effort to solve a vehicle sag concern. Shock absorbers are, by design, hydraulic damping units only and unlike suspension springs, do not support any suspension loads. Therefore, replacing a shock absorber will not correct a vehicle sag concern. 5. Road test the vehicle to confirm the customer concern. 6. Make sure the shock absorber is securely and properly installed. 7. Check the shock absorber insulators for damage and wear. 8. Replace any worn or damaged insulators and tighten attachments to the specified torque (on a shock absorber which incorporates internal insulators, replace the shock absorbers). 9. Tighten the shock absorber attachments to the specified torque. 10. Inspect the shock absorber for evidence of fluid leakage. Leakage is a condition in which the entire shock body is covered with oil, and the oil will drip the shock onto the pavement. A light film of oil (weepage) on the upper portion of the front shock absorber is permissible and is a result of proper shock lubrication. Weepage is a condition in which a thin film of oil may be deposited on the shock outer tube (body) and is normally noticed due to the collection of dust in this, area. Front shock absorbers which exhibit this weepage condition are functional units and should not be replaced. 11. If leakage exists: - Make sure the fluid observed is not from sources other than the front shock absorber. - Replace the worn or damaged front shock absorber. 12. Disconnect the lower end of the shock absorber. 13. Extend and compress the shock absorber as fast as possible, using as much travel as possible. Action should become smooth and uniform throughout each stroke. Higher resistance on extension than on compression is a normal condition. - Faint swish noises are also normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7322 Suspension Strut / Shock Absorber: Component Tests and General Diagnostics Bench Test The front shock absorbers are gas-pressurized, which results in their being fully extended when not restrained. If a front shock absorber does not fully extend, it is damaged and should be replaced. With the front shock absorber in the normal upright position, compress it and allow it to extend three times to purge the pressure chamber of any gas that may have been introduced during handling. Place the front shock absorber right side up in a vise. Hand-stroke the front shock absorber as fast as possible using as much travel as possible. Action should be smooth and uniform throughout each stroke. Higher resistance on extension than on compression is normal. The following conditions are abnormal: A lag or skip at a reversal of travel near mid-stroke when the front shock absorber is properly primed and in the installed position. - Seizing. - Noise, other than a faint swish, such as a clicking upon fast stroke reversal. - Excessive fluid leakage. - With rod fully extended, any lateral motion of rod in relation to outer cylinder. If front shock absorber action remains erratic after purging air, install a front shock absorber, replacing only the damaged front shock absorber. Front shock absorbers do not need to be replaced in pairs. Hoist Check WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Noise: Check for loose/damaged suspension or shock attachments when locating a noise symptom. Verify that all the attachments or the suspension components and the front springs and front shock absorbers are in good condition and tight. Replace any worn or damaged parts or components. 2. Bottom/Hopping: Check the condition of the rubber suspension travel stops (front suspension bumpers). Examine them for evidence of previous overload or damaged components; replace them if they are worn or missing. 3. Force-Check: Support the front axle and remove the lower front shock attachment. Stroke the front shock body using as much travel as possible. The action should be smooth and uniform throughout each stroke. Damping forces should be equivalent on both sides of the vehicle. 4. Replace only the worn or damaged front shock absorber. In the past, it was recommended that front shock absorbers be replaced in pairs if one unit became unserviceable. Improved sealing, new materials, design, and improved rod machining and hardening techniques have added to the reliability of shock absorbers. Therefore, front shock absorbers no longer need to be replaced in pairs when only one unit is not serviceable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber Air Shock Absorber Removal and Installation NOTE: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension switch. 1. Deflate the air suspension system. 2. Raise and support the vehicle. Front Air Shock Absorber 3. On LH air shock removal only, disconnect the top of the front height sensor from the upper frame bracket. 4. Remove the air shock lower nut and bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7325 5. Disconnect the air spring solenoid air line. - Compress the quick connect locking ring and pull out the air line. 6. Remove the air shock upper nut, grommet and the air shock. 7. NOTE: After installing the air shock, it is necessary to inflate the air suspension system. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7326 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7327 Suspension Strut / Shock Absorber: Service and Repair Rear Removal 1. WARNING: electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Remove the tire and wheel assembly. 3. Use the Hi-Lift Jack to support the rear axle. 4. Remove the upper shock absorber nut and bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7328 5. Remove the lower shock absorber nut, bolt and the shock absorber. Installation 1. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and allow the wheel to come off while the vehicle is in motion, causing loss of control. NOTE: Tighten the lug nuts in the sequence indicated in the illustration. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7329 Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber Removal 1. Hold the shock absorber stem and remove the upper front shock absorber nut, and washer assembly. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the shock absorber. 1 Remove the lower nut and bolt. 2 Remove the shock absorber. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7330 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Page 7331 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications TORQUE SPECIFICATIONS Axle Bumper Bolt ................................................................................................................................. ..................................... 34-46 Nm (26-34 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Specifications Torque Rod: Specifications TORQUE SPECIFICATIONS Trackbar To Rear Axle Bolt .............................................................................................................................................. 170-230 Nm (125-170 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Specifications > Page 7338 Torque Rod: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, Jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor, if so equipped. 1 Disconnect the electrical connector. 2 Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. 3. Remove the RH trackbar bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Specifications > Page 7339 4. Remove the LH trackbar nut and bolt. 5. Remove the trackbar from the vehicle. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications GENERAL SPECIFICATIONS Torsion Bar Adjustment Bolt From Bottom Of Torsion Bar Adjuster ............................................................................................................................................. 40 mm (1.6 inch) TORQUE SPECIFICATIONS Torsion Bar Crossmember Support Bolts .................................................................................................................................. 40-54 Nm (29-40 ft. lbs.) Torsion Bar Crossmember Support Nuts ................................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7343 Torsion Bar: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Make preliminary adjustment references. 1 Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2 Measure and record the length. 3. Relieve tine torsion bar tension. 1 Remove the torsion bar adjuster bolt. 2 Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. 4 Remove the torsion bar adjuster nut. 5 Remove the Torsion Bar Tool. 6 Remove the torsion bar adjuster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7344 4. Remove the torsion bars. 1 Remove the torsion bar crossmember support bolts and nuts. 2 Remove the torsion bar crossmember support. 3 Remove the torsion bars. Installation 1. Install the torsion bar. 1 Position the torsion bars. 2 Position the torsion bar crossmember support. 3 Install the torsion bar crossmember support bolts and nuts. 2. Load the torsion bar. 1 Install the torsion bar adjuster. Turn the torsion bar adjuster until the reference marks align. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7345 2 Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3 Tighten the Torsion Bar Tool to load the torsion bar. 4 Install the torsion bar adjuster nut. 5 Install the torsion bar adjuster bolt. 6 Remove the Torsion Bar Tool. 3. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7346 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7351 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7352 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7353 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7354 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7355 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7356 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7357 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7358 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7359 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7360 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7361 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7362 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7363 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7364 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7365 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7366 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7367 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7368 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7369 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7370 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7371 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7372 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7373 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7374 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7375 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7376 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7377 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7378 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7379 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7380 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7381 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7383 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7385 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7386 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7387 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7388 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7389 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7390 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7391 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7392 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7394 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7395 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7396 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7399 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7401 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7402 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7404 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7405 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7406 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7407 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7408 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7409 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7411 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7412 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7413 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7414 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7415 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7416 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7417 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7418 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7419 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7420 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7421 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7422 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7423 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7424 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7425 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7426 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7427 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7428 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7430 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7433 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7434 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7435 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7436 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7437 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7438 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7439 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7440 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7441 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7442 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7443 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7444 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7445 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear Wheel Bearing: Specifications 8.8 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear > Page 7448 Wheel Bearing: Specifications 9.75 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 7449 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear Wheel Bearing: Service and Repair 8.8 Inch Ring Gear Removal 1. Remove the axle shafts. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 7452 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 7453 Wheel Bearing: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear axle bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 7454 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 7457 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft Hub Nut 188 - 254 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation WARNING ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. ^ The jacking point is a raised boss located on the front suspension lower arm. The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. The rear jacking points are located on the rear axle. CAUTION: Never use the differential housing as a lifting point. Lifting WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7466 HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7467 Vehicle Lifting: Service and Repair JACKING WARNING ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. ^ The jacking point is a raised boss located on the front suspension lower arm. The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. The rear jacking points are located on the rear axle. CAUTION: Never use the differential housing as a lifting point. Lifting Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7468 WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications TORQUE SPECIFICATIONS Spare Tire Carrier Bolts ............................................................................................................................................................. 23-32 Nm (17-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 7473 Spare Tire: Service and Repair SPARE TIRE CARRIER REMOVAL 1. Lower the spare tire. 1 Insert the drive end of the jack handle through the opening left of the license plate. 2 Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. 1 Slide the retainer through the center of the spare tire assembly. 2 Remove the spare tire assembly. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Remove the spare tire carrier. 1 Remove the bolts. 2 Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 7474 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7479 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7480 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7481 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7482 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7483 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7484 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7485 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7486 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7487 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7488 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7489 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7490 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7491 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7492 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7493 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7495 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7496 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7497 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7498 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7499 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7500 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7501 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7502 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7503 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7504 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7505 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7506 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7507 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7508 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7509 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7510 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7511 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7512 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7513 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7514 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7515 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7516 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7517 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7518 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7519 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7520 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7521 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7522 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7523 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7524 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7525 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7526 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7527 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7528 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7529 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7530 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7531 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7532 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7533 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7534 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7535 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7536 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7537 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7538 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7539 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7540 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7541 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7542 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7543 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7544 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7545 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7546 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7547 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7548 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7549 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7550 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7551 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7552 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7553 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7554 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7555 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7556 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7557 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7558 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7559 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7560 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7561 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7562 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7563 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7564 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7565 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7566 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7567 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7568 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7569 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7570 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7571 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7572 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7573 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7574 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7575 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7576 Wheels: Specifications GENERAL SPECIFICATIONS Cast Aluminum .................................................................................................................................... ................................................................ 17 x 7.5J Steel .................................................................... .................................................................................................................................................... 16 x 7J Styled Aluminum ............................................................................................................................. ....................................................................... 16 x 7J Styled Argent Steel ......................................... ........................................................................................................................................................ 16 x 7J Wheel Offset ................................................................................................................................ ........................................................................... 14 mm Wheel Rim Runout (Radial Or Lateral) ........................................................................................................................................... 1.12 mm (0.044 inch) Maximum Balance Weight [a] .......................................................................................... ............................................................................. 170 g (6 oz.) [a] Total Of Inner And Outer Wheel Flanges Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information Wheels: Technician Safety Information WARNING: Never run the engine with one wheel off the ground, for example, when changing a tire. The wheel resting on the ground could cause the vehicle to move. WARNING: The tire and wheel must always be properly matched. It is very important to determine the size of each component before any assembly operations commence. Do not mount a 16-inch tire on a 16.5-inch wheel. Failure to adhere to these instructions can result in an explosive separation and cause serious bodily injury or death. Do not mount a 16.5 inch tire on a 16 inch wheel. The tire can come off without warning. WARNING: Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure these products have not been used. WARNING: Use only wheels and lug nuts that have been designed for the correct model year Ford trucks. Aftermarket wheels or lug nuts may not fit or function properly, and can cause personal injury or damage the vehicle. WARNING: Always wear safety goggles or a face shield when performing any work with tire and wheel assemblies. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information > Page 7579 Wheels: Vehicle Damage Warnings WARNING: Retighten the lug nuts at 800 km (500 miles) after any wheel change or any time the lug nuts are loosened. WARNING: Failure to retighten lug nuts at the mileage specified can allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specification ESR-M5B194-B . CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core . Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Page 7580 Wheels: Description and Operation WARNING: Do not mix different types of tires such as radial, bias, or bias-belted, on the same vehicle except in emergencies (temporary spare usage). Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. Replacement tires should follow the recommended: tire sizes. - speed rating. - load range. - radial construction type. Use of any over tire size or type may seriously affect: ride. - handling - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - wheel bearing life. - brake cooling. Wheels need to be replaced when: bent. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. A two-piece lug nut is used, containing the nut and a washer. Wheel and tire assemblies are attached by five noncentering lug nuts. When balancing wheels and tires, use T-type balancing weights. The spare tire is mounted under the frame. The valve stem should be on the top side of the tire to reduce the possibility of accidental valve stem air leakage. To equalize tire wear, rotate the tires periodically. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks Wheels: Service and Repair Leaks 1. CAUTION: Do not attempt to repair aluminum wheels that leak air. If repairs are made to the wheel, the structural integrity of the wheel can be lost. Replace any aluminum wheel that leaks air. 2. Replace or repair any wheel that leaks air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 7583 Wheels: Service and Repair Replacements Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting of the wheel or the surface of the wheel hub or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface and wheel centering O-ring. 2. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the tire and wheel assembly. 1 Inspect the wheel centering O-ring. Replace if damaged. 2 Position the tire and wheel assembly. 3 Install the lug nuts, hand-tight, then lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 7584 3. Tighten the lug nuts in sequence. 4. Install the center cap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7589 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7590 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7591 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7592 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7593 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7594 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7595 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7596 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7597 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7598 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7599 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7600 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7601 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7602 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7603 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7604 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7605 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7606 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7607 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7608 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7609 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7610 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7611 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7612 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7613 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7614 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7615 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7616 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7617 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7618 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7619 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7620 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7621 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7622 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7623 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7624 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7625 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7626 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7627 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7628 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7629 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7630 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7631 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7632 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7633 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7634 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7635 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7636 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7637 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7638 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7639 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7640 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7641 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7642 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7643 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7644 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7645 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7646 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7647 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7648 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7649 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7650 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7651 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7652 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7653 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7656 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7657 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7663 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7664 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7665 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7666 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7667 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7668 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7669 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7670 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7671 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7672 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7673 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7674 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7675 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7676 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7677 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7678 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7679 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7680 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7681 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7682 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7683 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear Wheel Bearing: Specifications 8.8 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > 8.8 Inch Ring Gear > Page 7686 Wheel Bearing: Specifications 9.75 Inch Ring Gear - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 7687 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear Wheel Bearing: Service and Repair 8.8 Inch Ring Gear Removal 1. Remove the axle shafts. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 7690 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 7691 Wheel Bearing: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the inner wheel bearing oil seal by itself. Always remove the inner wheel bearing oil seal and the rear wheel bearing at the same time. NOTE: If the inner wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Installation 1. Lubricate the new rear axle bearing. ^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 7692 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 7695 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft Hub Nut 188 - 254 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA99V099000 > Apr > 00 > Recall 99V099000: Wheel Lug Retorqueing Wheel Fastener: Recalls Recall 99V099000: Wheel Lug Retorqueing Vehicle Description: Sport utility vehicles equipped with four-wheel-drive (4x4), 17" chrome steel wheels. The clamp load can be lost on the wheel lugs due to insufficient wheel contact area with the hub. In some cases, the contact area can deform, resulting in a loss of lug nut torque. Loss of lug nut torque can cause vibration or separation of a wheel and tire from the vehicle. Dealers will re-torque the wheel lugs to proper specifications and also install a label that specifies that the wheel lugs be torqued to 110 lb-ft any time the wheel is removed. Owner notification began May 7, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque Technical Service Bulletin # 99S12 Date: 990501 Recall - Chrome Steel Wheel Lug Nut Torque 99512 SAFETY RECALL Certain 1999 Expedition and Navigator 4 x 4 Vehicles with Chrome Steel Wheels Lug Nut Torque ^ Recall/Service Program Information ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7712 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7713 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement could result in a civil penalty of up to $1,100 per vehicle. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator and Expedition owners qualify for the "Special Customer Handling Procedure. Before calling vehicle owners, review Attachment IV to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Promptly correct other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION Enter claims using DWE. See ACESII Manual for claims preparation and submission procedures. To claim for the "Special Customer Handling", follow the instructions on Attachment IV. Attachment II - Labor and Parts Information REFUNDS ^ Ford is offering a full refund to customers who paid for vehicle repairs that were caused by loose wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7714 ^ See ACESII manual for refund procedures and information. LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An initial supply of warning labels was included with the original Safety Recall Bulletin, 99S12. Additional warning labels can be obtained free of charge by calling 1-800-325-5621. Attachment III - Technical Information OVERVIEW Some vehicles affected by this recall are not equipped with chrome steel wheels. In performing this recall, inspect each affected vehicle to determine if it is equipped with chrome steel wheels. If the vehicle is equipped with chrome steel wheels, perform the service procedure shown. If the vehicle is not equipped with chrome steel wheels, it should be returned promptly to the customer. INSPECTION PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7715 1. Visually inspect the wheels on the vehicle and compare to Figure 1. If the wheels on the vehicle are: ^ identical to either of those shown in Figure 1, proceed with the service procedure. ^ different from those shown in Figure 1, the vehicle does not require service. Return the vehicle to the customer without delay. SERVICE PROCEDURES CAUTION: POWER TOOLS OR TORQUE STICKS MUST NOT BE USED. ONLY USE A CLICK-TYPE OR DIAL-TYPE TORQUE WRENCH TO PERFORM THIS OPERATION NOTE: Tighten lug nuts using the standard STAR pattern as specified in the appropriate service manual. CAUTION: THE LUG NUTS MUST BE COOL ENOUGH TO TOUCH BEFORE PERFORMING THIS PROCEDURE. IF THIS PROCEDURE IS PERFORMED ON LUG NUTS THAT ARE NOT COOL ENOUGH TO TOUCH, INACCURATE TORQUE READINGS AND WHEEL CLAMP LOADS MAY RESULT. 1. Remove the center caps from each wheel. 2. Check for minimum installed wheel lug nut torque as follows: A. Set the torque wrench to 88 Nm (65 lb-ft). B. Attempt to tighten all lug nuts. ^ If any lug nut starts to rotate on the stud before the minimum torque of 88 Nm (65 lb-ft) is reached, call the Recall Hotline at 1-800-325-5621 for further instruction. ^ If all of the lug nuts on each wheel do NOT rotate before the torque wrench reaches 88 Nm (65 lb-ft), proceed with step 3. 3. Tighten all wheel lug nuts to 149 Nm (110 lb-ft) following the standard STAR pattern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7716 4. Using alcohol and a clean shop cloth, thoroughly clean the center portion of the wheels in the locations shown in Figures 2 and 3. 5. For U.S. vehicles, apply one (English) label to each wheel at the location shown. See Figure 2. 6. For Canadian vehicles, apply two (2) labels (one English and one French) to each wheel in the locations shown. See Figure 3. 7. Reinstall the center caps on each wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7717 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7718 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA99V099000 > Apr > 00 > Recall 99V099000: Wheel Lug Retorqueing Wheel Fastener: All Technical Service Bulletins Recall 99V099000: Wheel Lug Retorqueing Vehicle Description: Sport utility vehicles equipped with four-wheel-drive (4x4), 17" chrome steel wheels. The clamp load can be lost on the wheel lugs due to insufficient wheel contact area with the hub. In some cases, the contact area can deform, resulting in a loss of lug nut torque. Loss of lug nut torque can cause vibration or separation of a wheel and tire from the vehicle. Dealers will re-torque the wheel lugs to proper specifications and also install a label that specifies that the wheel lugs be torqued to 110 lb-ft any time the wheel is removed. Owner notification began May 7, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque Technical Service Bulletin # 99S12 Date: 990501 Recall - Chrome Steel Wheel Lug Nut Torque 99512 SAFETY RECALL Certain 1999 Expedition and Navigator 4 x 4 Vehicles with Chrome Steel Wheels Lug Nut Torque ^ Recall/Service Program Information ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7730 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7731 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement could result in a civil penalty of up to $1,100 per vehicle. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator and Expedition owners qualify for the "Special Customer Handling Procedure. Before calling vehicle owners, review Attachment IV to familiarize yourself with this special handling procedure. PROMPTLY CORRECT Promptly correct other eligible vehicles that are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION Enter claims using DWE. See ACESII Manual for claims preparation and submission procedures. To claim for the "Special Customer Handling", follow the instructions on Attachment IV. Attachment II - Labor and Parts Information REFUNDS ^ Ford is offering a full refund to customers who paid for vehicle repairs that were caused by loose wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7732 ^ See ACESII manual for refund procedures and information. LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information An initial supply of warning labels was included with the original Safety Recall Bulletin, 99S12. Additional warning labels can be obtained free of charge by calling 1-800-325-5621. Attachment III - Technical Information OVERVIEW Some vehicles affected by this recall are not equipped with chrome steel wheels. In performing this recall, inspect each affected vehicle to determine if it is equipped with chrome steel wheels. If the vehicle is equipped with chrome steel wheels, perform the service procedure shown. If the vehicle is not equipped with chrome steel wheels, it should be returned promptly to the customer. INSPECTION PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7733 1. Visually inspect the wheels on the vehicle and compare to Figure 1. If the wheels on the vehicle are: ^ identical to either of those shown in Figure 1, proceed with the service procedure. ^ different from those shown in Figure 1, the vehicle does not require service. Return the vehicle to the customer without delay. SERVICE PROCEDURES CAUTION: POWER TOOLS OR TORQUE STICKS MUST NOT BE USED. ONLY USE A CLICK-TYPE OR DIAL-TYPE TORQUE WRENCH TO PERFORM THIS OPERATION NOTE: Tighten lug nuts using the standard STAR pattern as specified in the appropriate service manual. CAUTION: THE LUG NUTS MUST BE COOL ENOUGH TO TOUCH BEFORE PERFORMING THIS PROCEDURE. IF THIS PROCEDURE IS PERFORMED ON LUG NUTS THAT ARE NOT COOL ENOUGH TO TOUCH, INACCURATE TORQUE READINGS AND WHEEL CLAMP LOADS MAY RESULT. 1. Remove the center caps from each wheel. 2. Check for minimum installed wheel lug nut torque as follows: A. Set the torque wrench to 88 Nm (65 lb-ft). B. Attempt to tighten all lug nuts. ^ If any lug nut starts to rotate on the stud before the minimum torque of 88 Nm (65 lb-ft) is reached, call the Recall Hotline at 1-800-325-5621 for further instruction. ^ If all of the lug nuts on each wheel do NOT rotate before the torque wrench reaches 88 Nm (65 lb-ft), proceed with step 3. 3. Tighten all wheel lug nuts to 149 Nm (110 lb-ft) following the standard STAR pattern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7734 4. Using alcohol and a clean shop cloth, thoroughly clean the center portion of the wheels in the locations shown in Figures 2 and 3. 5. For U.S. vehicles, apply one (English) label to each wheel at the location shown. See Figure 2. 6. For Canadian vehicles, apply two (2) labels (one English and one French) to each wheel in the locations shown. See Figure 3. 7. Reinstall the center caps on each wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7735 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7736 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7737 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 99S12 > May > 99 > Recall - Chrome Steel Wheel Lug Nut Torque > Page 7738 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener Wheel Fastener: Specifications Wheel Fastener TORQUE SPECIFICATIONS Wheel Lug Nuts: 113-153 Nm (83-112 ft. lbs.) GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric): M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener > Page 7741 Wheel Fastener: Specifications Wheel Stud GENERAL SPECIFICATIONS Wheel Stud And Lug Nuts (Metric) ........................................................................................................................................... M12 x 1.75 - 19 mm Hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 7742 Wheel Fastener: Service and Repair Removal 1. Remove the wheel hub. 2. CAUTION: Do not press on the bearing when removing or installing wheel studs. Remove the damaged wheel studs. Installation 1. CAUTION: Do not press on the bearing when removing or installing wheel studs. Install the new wheel studs. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Suction Accumulator Clamp Bracket Bolt 9-11.2 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7747 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is riot required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet lube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. ^ A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. ^ As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. ^ A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. ^ A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. ^ A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7748 is installed in the fitting so that the A/C cycling switch can be removed without recovering the A/C system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7749 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. 3. Remove the junction block splash shield. 4. Disconnect the cable ends. 5. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 6. Disconnect the A/C cycling switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7750 7. Disconnect the manifold and tube fitting. CAUTION: Use a back-up wrench to prevent damage to the tubes. 8. Remove the suction accumulator bracket clamp bolt. 9. Disconnect the suction accumulator/drier spring lock coupling from the A/C evaporator core. 10. Remove the suction accumulator/drier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7751 11. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1 To install, reverse the removal procedure. ^ Service the new suction accumulator/drier with the correct amount of PAG Compressor Oil F7AZ-19589-D or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary A/C Blend Actuator Air Door Actuator / Motor: Diagrams Auxiliary A/C Blend Actuator Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary A/C Blend Actuator > Page 7757 Air Door Actuator / Motor: Diagrams Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary A/C Blend Actuator > Page 7758 Air Door Actuator / Motor: Diagrams Console Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 7759 Air Door Actuator / Motor: Description and Operation The A/C electric blend door actuator is located on the plenum assembly. ^ Its function is to move the air temperature blend door on command from the control assembly. ^ The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. ^ A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the electronic automatic temperature control (EATC) module and is compared to the desired wiper voltage determined by the EATC module. The control ]nodule then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the desired wiper voltage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator Air Door Actuator / Motor: Service and Repair Air Door Actuator Air Inlet Door REMOVAL 1. Remove the plenum chamber. 2. Remove the air inlet door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the vacuum control motor screws. 3 Remove the air inlet door vacuum control motor. ^ Rotate the vacuum control motor to disconnect the vacuum control motor rod from air inlet door lever. INSTALLATION 1. To install, reverse the removal procedure. Defrost/Panel REMOVAL 1. Remove the panel/defrost door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the pushnut. 3 Remove the vacuum control motor screws. 4 Remove the panel/defrost door vacuum control motor. INSTALLATION 1. To install, reverse the removal procedure. Floor/Panel REMOVAL 1. Remove the floor duct. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7762 2. Remove the panel/floor door vacuum control motor. 1 Disconnect the vacuum line connector. 2 Remove the vacuum control motor screws. 3 Slide the rod out of the door and remove the panel/floor door vacuum control motor. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7763 Air Door Actuator / Motor: Service and Repair Blend Door Motor Auxiliary Blend Door and Mode Door Actuator REMOVAL NOTE: The auxiliary blend door actuator is shown; the auxiliary mode door actuator is similar. 1. Remove the LH quarter trim panel. 2. Remove the electronic actuator. 1 Disconnect the connector. 2 Remove the screws. 3 Remove the electronic actuator. INSTALLATION 1. To install, reverse the removal procedure. Blend Door and A/C Dampner REMOVAL NOTE: The temperature blend door is shown; the A/C damper door is similar. 1. Remove the heater core. 2. Remove the A/C evaporator core. 3. Remove the temperature blend door actuator motor. 1 Remove the bolts. 2 Remove the temperature blend door actuator motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7764 4. Separate the air conditioning and heater housing assembly. 1 Remove the 12 bolts. 2 Separate the air conditioning and heater housing assembly. 5. Remove the temperature blend door. INSTALLATION 1. To install, reverse the removal procedure. Temperature Blend Door Actuator Removal All vehicles 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with floor console 2. Remove the floor console. All vehicles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7765 3. Remove the floor duct panel. - Remove the pin-type retainers and release the expander clip. 4. Remove the RH instrument panel brake. 1. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7766 2. Remove the bolt. 3. Remove the brace. 5. Remove the LH instrument panel lower nut and position the brace aside. 6. Disconnect the restraints control module (RCM) electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7767 7. Remove the RCM and bracket assembly. 1. Remove the bracket retaining bolts. 2. Remove the RCM and bracket assembly. Vehicles equipped with rear airflow duct 8. Cut the rear seat airflow duct along both sides. - Fold back carpet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7768 - Cut rear seat airflow duct. 9. Fold the air duct rearwards. All vehicles 10. Remove the floor duct. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7769 1. Remove the two screws (one each side). 2. Remove the floor duct. 11. Remove the electronic blend door actuator. 1. Disconnect the connector. 2. Remove the screws. 3. Pull down to release the actuator shaft and remove the electronic blend door actuator. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7770 1. Install the electronic blend door actuator. 1. Connect the actuator shaft. 2. Install the screws. 3. Connect the connector. 2. Install the floor duct. 1. Install the floor duct. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7771 2. Install the two screws (one each side). Vehicles equipped with rear airflow duct 3. Zip-tie the rear airflow duct to floor duct. 4. Reposition the carpet. All vehicles WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7772 5. Install the RCM and bracket assembly. 6. Connect the restraints control module (RCM) electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7773 7. Install the LH instrument panel lower nut. 8. Install the RH instrument panel brace. - Install the brace. - Install the nut. - Install the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7774 9. Install the floor duct panel. - Install the pin-type retainers and release the expander clip. Vehicles equipped with floor console 10. Install the floor console. All vehicles 11. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 7779 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Demister Adapter Screw 2-3 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the rear seat air flow duct. 2. Remove the RH instrument panel brace. 1 Remove the nut. 2 Remove the bolt. 3 Remove the brace. 3. Remove the LH instrument panel lower nut and position the brace aside. 4. Remove the floor duct. 1 Remove the two screws (one on each side). 2 Remove the floor duct. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7785 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7786 Air Duct: Service and Repair Rear Seat Air Flow REMOVAL 1. If equipped, remove the center console blower motor. 2. If equipped; remove the floor duct panel. ^ Remove the pin-type retainers and release the expander clip. 3. Remove the front seats. 4. Remove the kick panel and the sill trim. 5. Pull back the carpet. 6. Remove the pin-type retainers and remove the duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary Air Register: Service and Repair Auxiliary REMOVAL 1. Fabricate a removal tool from a 1/8 inch diameter rod. 2. Rotate the A/C register with the removal tool to align the retaining ears with the clearance openings and remove the A/C register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 7791 Air Register: Service and Repair Center REMOVAL 1. Remove the center instrument panel finish panel. 2. If equipped, disconnect the transfer case rotary control switch electrical connector. 3. Remove the center panel register(s). 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 7792 Air Register: Service and Repair Left REMOVAL 1. Remove the steering column cover panel. 2. Remove the headlamp switch. 3. Remove the LH instrument panel finish panel. 1 Remove the eight screws. 2 Remove the instrument panel finish panel. 4. Remove the LH panel register. 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the LH panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary > Page 7793 Air Register: Service and Repair Right REMOVAL 1. Remove the instrument panel. 2. Remove the RH panel register. 1 Remove the screws. 2 Remove the RH panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Sensor Bracket Bolt 9 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7797 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: ^ is located in front of the A/C condenser core near the center of the vehicle. ^ contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the Electronic Automatic Temperature Control (EATC) module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7798 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Remove the pin-type retainers and remove the radiator sight shield. 2. Disconnect the connector. 3. Remove the bolt and remove the ambient air temperature sensor panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: Customer Interest A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: All Technical Service Bulletins A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Blower Motor Screws-Plenum 2-3.5 Nm Blower Motor Cover Screws-Plenum 1-2 Nm Blower Motor Nuts-Console 2.1-2.9 Nm Blower Motor Cover Screws-Console 2.1-2.9 Nm Blower Motor Duct Screws-Console 2.1-2.9 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor > Page 7817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor > Page 7818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System Blower Motor: Description and Operation Auxiliary Blower Motor System The auxiliary air conditioning system contains a blower motor which is controlled by the heater blower motor switch on the front or rear auxiliary A/C control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System > Page 7821 Blower Motor: Description and Operation Floor Console Blower The floor console blower provides airflow to the rear sear passengers. Controls for the console blower are incorporated into the rear integrated control panel located in the rear of the floor center console. The controls adjust the console blower speed and the direction of airflow. The floor console blower is not available with auxiliary air conditioning. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System > Page 7822 Blower Motor: Description and Operation Heating and Defrosting Blower Motor The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor Blower Motor: Service and Repair Blower Motor Blower Motor-Plenum Removal and Installation All vehicles 1. Remove the RH lower instrument panel insulator. 2. Remove the passenger side scuff plate. 3. Remove the passenger side kick panel. 1. Position aside the weatherstrip. 2. Remove the passenger side kick panel. 4. Position back the carpet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7825 5. Using a suitable tool make a three-sided cut in the floor insulation below the blower motor and fold it back to provide clearance for the blower motor. Vehicles with EATC 6. Disconnect the aspirator tube and remove the screw. 7. Remove the aspirator tube extension. 1. Remove the screws. 2. Remove the aspirator tube extension. All vehicles 8. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7826 9. Remove the screws and remove the blower motor. 10. Remove the wheel from the blower motor. 1. Remove the clip. 2. Remove the blower wheel. 11. To install, reverse the removal procedure. Reseal the floor insulation using a suitable adhesive tape. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7827 Blower Motor: Service and Repair Blower Motor and Plenum REMOVAL 1. Remove the passenger side insulator panel. 2. If equipped, remove the aftermarket air filter. 3. If equipped, remove the mounting bracket for the removed cover. 4. Disconnect the christmas tree retainer from the motor mounting plate. 5. Disconnect the connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7828 6. Remove the blower motor cover. 1 Remove the three screws. 2 Pry to release the three tabs. 3 Remove the cover. 7. Remove the blower motor. 1 Remove the three screws. 2 Remove the blower motor. CAUTION: Carefully remove the blower motor so as not to damage the wheel. 8. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel. 9. Remove the gasket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7829 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7830 Blower Motor: Service and Repair Center Console Blower Motor REMOVAL 1. Remove the floor console. 2. Remove the floor console support braces. 1 Remove the eight screws. 2 Remove the braces. 3. Remove the blower motor duct. 1 Remove the screws. 2 Remove the duct. 4. Remove the blower motor assembly. 1 Remove the three nuts. 2 Remove the blower motor from the bottom of the console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7831 5. Disconnect the harness connectors. 6. Remove the blower motor resistor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the resistor. 7. Remove the blower motor lower duct cover. 1 Remove the five screws. 2 Remove the duct cover. 8. Remove the blower motor upper duct cover. 1 Remove the three bolts. 2 Remove the duct cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7832 9. Remove the blower motor. 1 Remove the two bolts. 2 Disconnect the connector. 3 Remove the blower motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7833 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Relay > Page 7838 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7841 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7842 Blower Motor Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7843 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Bolts 2.1-2.9 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors > Page 7849 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors > Page 7850 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 7851 Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: ^ The assembly is located on the passenger side of the plenum assembly behind the glove compartment. ^ Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds. ^ Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. ^ An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except HI. ^ The thermal limiter cannot be reset and is not serviceable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 7852 Blower Motor Resistor: Service and Repair REMOVAL 1. Remove the LH quarter trim panel access cover. 2. Disconnect the electrical connector. 3. Remove the bolts and remove the A/C blower motor resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 7857 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 7858 Blower Motor Switch: Diagrams Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Description and Operation Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: ^ A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. ^ An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. ^ The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. ^ The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Description and Operation > Page 7865 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. Disconnect the Control switch connector. 3. Remove the steering column cover panel. 4. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Description and Operation > Page 7866 5. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the LH instrument panel finish panel. 6. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 7. Remove the screw. 8. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Clutch Air Gap and Runout Compressor Clutch: Specifications A/C Clutch Air Gap 0.35-0.85 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Clutch Air Gap and Runout > Page 7872 Compressor Clutch: Specifications Compressor Clutch Hub Bolt 11-14 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7873 Compressor Clutch: Description and Operation A/C compressor and Clutch Assembly Compressor Clutch Components NOTE - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The FS-10 A/C compressor has the following characteristics: ^ A ten-cylinder swashplate design utilizing the tangential design mount. ^ Displacement of 154 cc (9.4 cubic inches) ^ A one-piece lip-type seal (installed from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. ^ Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. ^ Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. ^ The A/C compressor uses PAG Compressor Oil, F7AZ-19589-DA, or equivalent meeting Ford specification WSH-M1C231-B. This oil contains special additives required for the A/C compressor. ^ The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. The magnetic A/C clutch has the following characteristics: ^ It drives the compressor shaft. ^ When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. ^ The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7874 ^ When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch plate away from the A/C clutch pulley. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7875 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7876 Compressor Clutch: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7877 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Differential Bearing Cone Remover. 4 Remove the A/C clutch field coil. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7878 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7879 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 7884 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Differential Bearing Cone Remover. 4 Remove the A/C clutch field coil. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 7885 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 7886 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 7887 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-ring Remover. 3. Clean the compressor area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7891 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover Lip quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the Compressor Seal Remover into the inside diameter of the shaft seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7892 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the Seal Protector. Lubricate the shaft seal and the Seal Protector with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. Position the shaft seal and the Seal Protector over the A/C compressor shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7893 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Installer until seated. 5. Install the shaft seal snap ring. 6. Carry out the A/C Compressor- External Leak Test. 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7894 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations Compressor Clutch Diode HVAC: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations > Page 7898 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7902 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7903 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7904 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7905 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications Manifold Tube Bolt 18-24 Nm Manifold Tube Fitting 25.5-34.5 Nm Tube Bracket Nut 10-14 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7909 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Recover the refrigerant. 2. Remove the manifold and tube assembly. 1 Remove the manifold to compressor bolt. 2 Remove the manifold and tube assembly. 3. Disconnect the A/C pressure cut-off switch electrical connector. 4. Disconnect the manifold and tube fitting at the suction accumulator/drier. 5. Disconnect the A/C condenser core inlet line. 1 Remove the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7910 2 Disconnect the A/C condenser core inlet lines. 6. If equipped, remove the nut. 7. Remove the A/C pressure cut-off switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7911 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. ^ Apply Pipe Sealant with Teflon(R) D8AZ-19554A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to the threads of the A/C manifold retaining bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Control Assembly, HVAC Control Assembly: Diagrams Control Assembly, HVAC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Control Assembly, HVAC > Page 7916 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Control Assembly, HVAC > Page 7917 Control Assembly: Diagrams Electronic Climate Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System Control Assembly: Description and Operation Auxiliary Air Conditioning and Heating System The auxiliary A/C system has dual controls for the driver and rear passengers consisting of temperature, blower speed, and mode. The front auxiliary A/C control is mounted in the overhead console. The rear auxiliary A/C control is mounted in a separate console positioned on the roof trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 7920 Control Assembly: Description and Operation With Air Conditioning The climate control assembly has three system controls: ^ The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. ^ The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. ^ The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches Control Assembly: Service and Repair Climate Control Switches REMOVAL 1. Remove the control assembly. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the temperature blend control switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control switch. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob Will drop off as the blower motor switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7923 Control Assembly: Service and Repair Control Assembly - Electronic Automatic Temperature Control WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the control switch connector. 4. Remove the climate control head. 1 Remove the screws. 2 Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7924 5. Disconnect the climate control head. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7925 Control Assembly: Service and Repair Front Control Assembly REMOVAL 1. Remove the overhead console. 1 Remove the screw. 2 Carefully release the three clips and slide the overhead console forward. 3 Disconnect the electrical connectors. 2. Remove the auxiliary climate control assembly from the bezel. 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the climate control assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7926 Control Assembly: Service and Repair Rear Control Assembly REMOVAL 1. Remove the auxiliary climate control assembly. 1 Slide the assembly forward and downward. 2 Disconnect the electrical connectors. 2. Remove the auxiliary climate control assembly from the bezel. 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the climate control assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7927 Control Assembly: Service and Repair With Manual A/C REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. Disconnect the control switch connector. 4. Remove the screws from the Electronic Automatic Temperature Control (EATC) module. 5. Remove the EATC module. 1 Disconnect the electrical connectors. 2 Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 7928 3 Disconnect the vacuum harness connector and remove the EATC module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7933 Control Module HVAC: Diagrams Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the Electronic Automatic Temperature Control (EATC) module tells the A/C bower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: ^ Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. ^ Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 7936 Control Module HVAC: Description and Operation Electronic Climate Control Module The electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: ^ 11 push buttons ^ a blower speed override thumbwheel for manual input ^ a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) ^ an On-Board Diagnostic (OBD) feature to supply the technician with DTCs. These DTCs direct the technician to the inoperative component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Remove the kickpad. 3. Disengage the aspirator hose from the bracket. NOTE: Part shown out of vehicle position. 4. Disengage the blower motor speed control mounting bracket from the instrument panel. 5. Disconnect the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7939 6. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7940 Control Module HVAC: Service and Repair Electronic Climate Control Module WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the control switch connector. 4. Remove the climate control head. 1 Remove the screws. 2 Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7941 5. Disconnect the climate control head. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 7942 Control Module HVAC: Service and Repair Illumination Bulbs REMOVAL 1. Remove the Control assembly. 2. Unsnap the bezel and pivot it open. ^ To replace the general illumination bulbs, unscrew the lamp holder and remove the bulb. ^ To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. NOTE: Place the module upside down on a non-marring surface. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. ^ When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. ^ The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. ^ Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. ^ These O-ring seals are green in color and are made of special material. ^ Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. ^ A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. ^ The indicator ring may also be used during service operations to indicate connection of the coupling. ^ An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting Coupler HVAC: Service and Repair Peanut Fitting DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7948 2. Install the O-ring seal. 1 Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When properly assembled the male and female fittings should be flush. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7949 Coupler HVAC: Service and Repair Spring Lock Coupling Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling Clip. 2. Fit the Spring Lock Coupling Disconnect Tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting item the A/C tube lock coupling spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7950 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. Coupling Size Pad Size 3/8 inch 25 X 50 mm (1 X 2 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7951 1/2 inch 25 X 50 mm (1 X 2 inch) 5/8 inch 25 X 76 mm (1 X 3 inch) 3/4 inch 25 X 102 mm (1 X 4 inch) 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed motor drill. 6. Polish for one minute at moderate speed (less than 1500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. 1 Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7952 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the O-ring seals. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 1 Lubricate the O-ring seals with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7953 5. Install the A/C tube lock coupling clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Specifications Evaporator Case: Specifications Front Plenum Assembly Nuts (Passenger Side) 4-6 Nm Front Plenum Assembly Nuts (Engine Side) 4-6 Nm Front Plenum Top Screws 1.5-2.5 Nm Auxiliary Air Conditioning and Heater Assembly Bolts 6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications Outlet Line To Auxiliary Evaporator Case Line 8 Nm A/C Evaporator to Expansion Valve Lines 12.7-17.3 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary Evaporator Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear A/C evaporator core which operates in the same manner as the front A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary > Page 7962 Evaporator Core: Description and Operation With Manual A/C A/C Evaporator Core NOTE: Installation of a new suction accumulator/drier is riot required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. ^ A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. ^ The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. ^ Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. ^ This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7963 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C test fitting set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shutoff valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minutes evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degree the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and Stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. ^ If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. ^ If a small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. ^ If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core: Service and Repair Front REMOVAL NOTE - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. - If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Recover the refrigerant. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Remove the junction block splash shield. 5. Disconnect the cable ends. 6. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 7966 7. Disconnect the heater core hose couplings. 8. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. 9. Remove the RH A/C plenum demister adapter. 1 Remove the screw. 2 Remove the RH A/C plenum demister adapter. 10. Remove the heater core outlet bracket. 1 Remove the screws. 2 Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 7967 11. Remove the plenum assembly top. 1 Remove the 14 screws. 2 Remove the plenum assembly top. 12. Remove the A/C evaporator core from the plenum assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Service the replacement A/C evaporator core with the correct amount of PAG Compressor Oil F7ZF-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 7968 Evaporator Core: Service and Repair Auxiliary REMOVAL 1. Remove the air conditioning and heater assembly. Refer to: "Heater Core Case : Service and Repair" See: Heater Core Case/Service and Repair 2. Remove the auxiliary A/C evaporator lines. 3. Remove the evaporator/heater core access cover. 1 Remove the ten bolts. 2 Remove the evaporator/heater core access cover. 4. Remove the A/C evaporator core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 7969 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: A new A/C evaporator core orifice should be installed whenever a new compressor is installed. The A/C evaporator core orifice has the following characteristics: ^ It is located in the A/C evaporator core inlet tube. ^ It has filter screens located on the inlet and outlet ends of the tube body. ^ The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. ^ O-ring seals on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from by passing the A/C evaporator core orifice. ^ Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be installed as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 7973 Expansion Block/Orifice Tube: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. ^ For a fixed orifice tube, carry out Steps 2 and 3. ^ For a broken orifice tube, carry out Steps 4 and 5. 2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C Evaporator core orifice. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 7974 4. To remove a broken A/C evaporator core orifice, screw the end of the Broken Orifice Extractor into the broken A/C evaporator core orifice. 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. 1 Use PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool. 3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated. 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 7975 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications Expansion Valve: Specifications A/C Evaporator to Expansion Valve Lines 12.7-17.3 Nm Refrigerant Lines To Expansion Valve 12.7-17.3 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 7979 Expansion Valve: Description and Operation An A/C evaporator expansion valve automatically regulates the flow of refrigerant into the auxiliary A/C evaporator core. It is also the dividing point in the system between low- and high-pressure sides. The temperature sensing bulb measures the temperature of the refrigerant in the suction line and transmits it to the A/C evaporator expansion valve. This temperature variation regulates the refrigerant flow to the auxiliary A/C evaporator core. ^ When the bulb senses a high temperature, the A/C evaporator expansion valve opens and floods refrigerant through the auxiliary A/C evaporator core. ^ When the bulb senses a low temperature, the A/C evaporator expansion valve starts closing to shut off the refrigerant to the auxiliary A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 7980 Expansion Valve: Service and Repair REMOVAL 1. Recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the A/C evaporator core from the A/C evaporator expansion valve. 4. Disconnect the A/C lines and remove the thermostatic expansion valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7989 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7990 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7996 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7997 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7998 Heater Core: Specifications Heater Core Bracket Screws 1.5-2.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C system uses a rear heater core which operates in the same manner as the front heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary > Page 8001 Heater Core: Description and Operation Heating and Defrosting Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 8002 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: ^ the heater core may have an air pocket ^ the heater core may be plugged. ^ the thermostat may not be working correctly. Heater Core-Pressure Test Use the radiator/heater core pressure tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 8003 Heater Core-Bench Test Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heating and Defrosting Heater Core: Service and Repair Heating and Defrosting REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Disconnect the heater core hose couplings. 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter 6. Disconnect the vacuum line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heating and Defrosting > Page 8006 7. Remove the heater core bracket. 1 Remove the two screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heating and Defrosting > Page 8007 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heating and Defrosting > Page 8008 Heater Core: Service and Repair Auxillary Heating System Removal 1. Remove the air conditioning and heater assembly. Refer to: " Heater Core Case : Service and Repair" See: Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1. Remove the ten bolts. 2. Remove the evaporator/heater core access cover. 3. Remove the heater core. Installation 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications Plenum Assembly Nuts (Passenger Side) 4-6 Nm Plenum Assembly Nuts (Engine Side) 4-6 Nm Plenum Top Screws 1.5-2.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Front A/C Heater Core Case: Service and Repair Front A/C REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 3. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Disconnect the heater hose couplings. 6. Disconnect the refrigerant line spring lock couplings from the A/C evaporator cores. 7. Remove the plenum chamber nuts (engine side). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Front A/C > Page 8014 8.Disconnect the A/C vacuum hose from the A/C vacuum check valve. 9. Remove the plenum chamber nuts (interior). 10. Remove the plenum chamber. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Front A/C > Page 8015 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Front A/C > Page 8016 Heater Core Case: Service and Repair Auxiliary AUXILIARY AIR CONDITIONING AND HEATER ASSEMBLY REMOVAL 1. Recover the refrigerant. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 2. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the LH quarter trim panel. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair 4. Disconnect the electrical connectors. 5. Disconnect the heater core hose couplings. 6. Remove the evaporator case drain hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Front A/C > Page 8017 7. Disconnect the auxiliary A/C evaporator lines. 8. Remove the A/C outlet duct. 1 Remove the pin-type retainer. 2 Remove the A/C outlet duct. 9. Remove the auxiliary air conditioning and heater assembly. 1 Remove the three bolts. 2 Remove the auxiliary air conditioning and heater assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Front A/C > Page 8018 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8027 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8028 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8034 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8035 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8036 Heater Hose: Specifications Hose Clamp 2-3 Nm Front Auxiliary Heater Line Brackets 8 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8037 Heater Hose: Description and Operation Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8038 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line The auxiliary lines are two-piece tubes that are secured to the underbody of the vehicle. New auxiliary line kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line Heater Hose: Service and Repair Front Auxiliary Heater Outlet and Inlet Line REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Loosen the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Move the front fender splash shield to access the lines. 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8041 8. Disconnect the heater outlet line from the outlet hose coupling. 9. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. 10. Cut the heater outlet line where it crosses under the frame. 11. Cut the heater outlet line near the front wheel well opening. 12. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8042 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8043 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line NOTE: The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater outlet line. ^ Install the end with the blue tape over the flame. 2. Connect the heater outlet line peanut fitting. 1 Connect the fitting. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Install the end with the red tape over the frame. ^ Install the end with the yellow tape between the frame and the body vertical flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8044 NOTE: View shown with fender skirt removed for clarity. 4. Connect the heater water outlet line to the heater water outlet line. 1 Connect the fitting. 2 Loosely install the nut. 5. Install the heater water outlet line to the heater water outlet line. ^ Install the line through the wheel opening. NOTE: Fender skirt removed for clarity. 6. Connect the heater water outlet line to the heater water outlet line. 1 Connect the fitting. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8045 7. Tighten the three peanut fittings. 8. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION Verify that clearance exists between the frame and the lines to prevent component damage. - Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 9. Connect the heater water outlet line to the engine heater outlet hose coupling. 10. Install the bolts, the pin-type retainers and the front fender splash shield. 11. Install the wheel and tire assembly. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8046 Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retailer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8047 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESR-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8048 Heater Hose: Service and Repair Rear Auxiliary Heater Inlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8049 9. Remove the our me bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 12. Cut the heater inlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8050 13. Cut the heater inlet line near the rear crossmember. 14. Cut the heater inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8051 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8052 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the green tape over the rear axle between the frame crossmember and the body. 2. Connect the heater inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape between the frame crossmember and the floor pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8053 4. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the red tape between the frame and the body. 6. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. ^ Install the end with the green tape through the floor opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8054 8. Connect the heater inlet line to the heater inlet line. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8055 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8056 Heater Hose: Service and Repair Rear Auxiliary Heater Outlet Line REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8057 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 12. Cut the heater outlet line near the grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8058 13. Cut the heater outlet line near the rear cross member. 14. Cut the heater outlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8059 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8060 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape over the axle between the frame and the body. 2. Connect the heater outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the red tape between the frame and the floor pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8061 4. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. 1 Remove RH rear wheel and tire. 2 Install the end with blue tape between the frame and the body. 6. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. ^ Install the end with the hose through the floor opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8062 8. Connect the heater outlet line to the heater outlet line. 1 Connect the fittings. 2 Loosely install the nuts. 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8063 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater outlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8064 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Disconnect the heater core hose couplings. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Auxiliary Heater Outlet and Inlet Line > Page 8065 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Page 8066 Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Specifications A/C Compressor Pressure Relief Valve 3103 kPa Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > A/C High Pressure Safety Valve > Page 8071 High Pressure Safety Valve HVAC: Specifications A/C Compressor Pressure Relief Valve 3103 kPa Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Description and Operation A/C High Pressure Safety Valve A/C Compressor Pressure relief valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: ^ relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above). ^ prevent damage to the A/C compressor and other system components. ^ avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve > Page 8074 High Pressure Safety Valve HVAC: Description and Operation Compressor Relief Valve A/C Compressor Pressure relief valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: ^ relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above). ^ prevent damage to the A/C compressor and other system components. ^ avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C Line Bracket Nuts 6.8-9.2 Nm A/C Evaporator to Expansion Valve Lines 12.7-17.3 Nm Outline Line to Auxiliary Evaporator Case Line 8 Nm Refrigerant Lines To Expansion Valve 12.7-17.3 Nm Front Auxiliary Heater Line Brackets 8 Nm Front Auxiliary A/C Line Bracket 8 Nm Peanut Fitting Expansion Valve Refrigerant Lines 8 Nm Peanut Fitting Rear Heater lines 8 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8078 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: ^ The upstream side contains low pressure refrigerant gas. ^ The downstream side contains high pressure refrigerant gas. ^ An integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. ^ The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without recovering the A/C system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line Hose/Line HVAC: Service and Repair A/C Hose/Line REMOVAL 1. Recover the refrigerant. 2. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 3. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 4. Remove the tube bracket nut. 5. Remove the suction accumulator drier bracket clamp bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8081 6. Remove the evaporator to condenser tube. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8082 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Condenser To Evaporator Line REMOVAL 1. Recover the refrigerant. 2. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 3. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 4. Remove the tube bracket nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8083 5. Remove the suction accumulator drier bracket clamp bolt. 6. Remove the evaporator to condenser tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8084 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Front Auxiliary Evaporator Outlet and Inlet Line REMOVAL NOTE: The 5/8 inch front auxiliary evaporator outlet line is shown, the 3/8 inch front auxiliary evaporator inlet line is similar. 1. Recover the refrigerant from the system. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the front fender splash shield. 6. Remove the three line bracket retaining nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8085 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 8. Disconnect the 5/8 inch auxiliary outlet line from the suction side of the A/C manifold and tube assembly. 1 Remove the nut. 2 Disconnect the line. 9. Disconnect the front auxiliary outlet line from the rear auxiliary line. 1 Remove the nut. 2 Disconnect the line. 10. Remove the front auxiliary evaporator outlet line. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8086 1. Install the front auxiliary evaporator outlet line. 2. Connect the front auxiliary outlet line to the rear auxiliary line. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting securely into the torque retention bracket. 3. Connect the front auxiliary outlet line to the suction side of the A/C manifold and tube assembly. 1 Connect the line. 2 Install the nut. 4. Install the line brackets. 1 Position the bracket. 2 Install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8087 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 5. Install the bolts, the pin-type retainers and the front fender splash shield. 6. Lower the vehicle. 7. Turn on the air suspension switch, if equipped. 8. Evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging Rear Auxiliary Evaporator Inlet Line REMOVAL 1. Recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8088 8. Remove the four line bracket retaining nuts. 9. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. 11. Cut the 3/8 inch evaporator inlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8089 12. Cut the 3/8 inch evaporator inlet line near the rear crossmember. 13. Cut the 3/8 inch evaporator inlet line forward of the rear wheel opening. 14. Cut the 3/8 inch evaporator inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: Lay out new lines in vehicle position to assist in installation. 1. Install the inlet line. ^ Install the end with the hose over the rear axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8090 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8091 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line NOTE: The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 2. Connect the inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. 3. Install the inlet line. ^ Starting from the rear of the vehicle, insert the end with the orange tape between the frame and the body. 4. Connect the inlet line to the inlet line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8092 1 Connect the inlet lines. 2 Loosely install the nut. 5. Install the inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the yellow tape between the frame and the body. 6. Connect the inlet line to the inlet line. ^ Connect the fitting and loosely install the nut. 7. Install the inlet line. ^ Install the end without tape through the floor. 8. Connect the inlet line to the inlet line. 1 Connect the me. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8093 9. Tighten the four peanut fittings. 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Connect the inlet line to the auxiliary evaporator case line. 14. Install the grommet seal and retainer. NOTE: Make sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Install the quarter trim access panel. 16. Evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging 17. Install the spare tire. Rear Auxiliary Evaporator Outlet Line REMOVAL NOTE: Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8094 1. Recover the refrigerant. 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. 8. Lower the muffler heat shield. 1 Remove the two front nuts. 2 Lower the heat shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8095 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the 5/8 inch outlet line peanut fitting that is located outboard of the side rail. 1 Remove the nut. 2 Disconnect the line. 12. Cut the 5/8 inch evaporator cutlet line near the A/C line grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8096 13. Cut tile 5/8 inch evaporator outlet line near the rear crossmember. 14. Cut the 5/8 inch evaporator outlet line forward of the rear wheel opening. 15. Cut the 5/8 inch evaporator outlet line between the frame and the muffler heat shield. 16. Remove and discard the cut sections. INSTALLATION NOTE - Lay out new lines in vehicle position to assist in installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8097 Refrigerant Lines: Part 1 0f 2 Item Description 1 Green tape 2 Front auxiliary heater inlet line 3 Blue tape 4 Front auxiliary heater inlet line 5 White tape (bracket locations) 6 Orange tape 7 Front auxiliary heater inlet line 8 Rear auxiliary heater inlet line 9 Rear auxiliary evaporator outlet line 10 Rear auxiliary beater inlet line 11 Violet tape 12 Rear auxiliary evaporator outlet line 13 Front auxiliary heater outlet line 14 Red tape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8098 15 Rear auxiliary heater inlet line 16 Rear auxiliary heater outlet line 17 Rear auxiliary evaporator outlet line 18 Rear auxiliary evaporator inlet line 19 Yellow tape 20 Rear auxiliary evaporator inlet line 21 Rear auxiliary evaporator outlet line 22 Rear auxiliary evaporator outlet line 23 Rear auxiliary evaporator inlet line 24 Rear auxiliary evaporator inlet line 25 Rear auxiliary heater outlet line 26 Rear auxiliary heater inlet line 27 Rear auxiliary heater inlet line 28 Rear auxiliary heater outlet line 29 Front auxiliary heater outlet line 30 Front auxiliary heater outlet line - The illustration shows the Multiple-Piece Auxiliary A/C Heater Line Kit. 1. Install the outlet line over the frame. ^ Install the end with violet tape between the frame and the body. 2. Connect the outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. 3. Install the outlet line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8099 ^ Starting from the rear of the vehicle install the end with the violet tape over the frame crossmember and between the main member and the muffler heat shield. 4. Correct the outlet line peanut fitting to the outlet line. 1 Connect the outlet lines. 2 Loosely install the nut. 5. Install the outlet line. ^ Starting from the rear of the vehicle, install the end with the yellow tape between the frame and the muffler heat shield. 6. Connect the outlet line peanut fitting to the outlet line. ^ Connect the fitting and loosely install the nut. 7. Install the outlet line. 1 Remove the RH rear wheel and tire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8100 2 Install the end with the orange tape between tie frame and the body through the rear wheel opening. 8. Connect the outlet line peanut fitting to the outlet line. ^ Connect the fitting and loosely install the nut. 9. Install the outlet line. ^ Install the end of the tube with no tape through the floor. 10. Connect the outlet line peanut fitting to outlet line. ^ Connect the fitting and loosely install the nut. 11. Tighten the five peanut fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Hose/Line > Page 8101 12. Install the line brackets. 1 Position tile bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 13. Install the muffler heat shield. 1 Position the shield 2 Install the nuts. 14. Lower the vehicle. 15. Turn the air suspension switch on, if equipped. 16. Connect the outlet line to the auxiliary evaporator case line. 17. Install the grommet seal and retainer. NOTE: Maker sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 18. Install the quarter trim access panel. 19. Evacuate and charge the A/C system. See: Service and Repair/Evacuation and Charging 20. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 8102 Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8107 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8108 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8109 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8110 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications System Capacity R-134a 62 oz (US) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8113 Refrigerant: Fluid Type Specifications Refrigerant............................................................................................................................................ ........................................................................R134a Ford Part Number ................................................................................................................................ ..................................................................... YN-19 Ford Specification ................................................................................................................................ ................................................... WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Without Auxiliary .................................................................................................................................. .......................................................... 266 ml (9 oz) With Auxiliary ...................................................... ......................................................................................................................................... 414 ml (14 oz) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8118 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil...................................................................................................................................... ...Polyalkylene Glycol (PAG) Oil (R-134a Systems) Ford Part Number ........................................................................................................................................................... F7AZ-19589-AD (MC-YN-12C) Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications Pressure Cut Off Switch 6.8-13.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8123 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Pressure Cut-Off Switch Opens 2896 kPa Approximately A/C Pressure Cut-off Switch Closes 1724 kPa Approximately A/C Cycling Switch Close Maximum 324 kPa A/C Cycling Switch Open Minimum 152 kPa Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. ^ A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. ^ This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. ^ When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. ^ It is not necessary to recover the refrigerant system to remove the A/C pressure cut-off switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 8126 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). ^ The contacts close when the suction pressure rises to 276-324kPa (40-47 psi). ^ When the A/C cycling switch contacts close, the A/C clutch field coil is energized. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to recover the refrigerant system to remove the A/C cycling switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the junction block splash shield. 3. Disconnect the cable ends. 4. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 5. Disconnect the A/C cycling pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8129 6. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Carry out the refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8130 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. 1 Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Relay > Page 8136 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 8139 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 8140 Blower Motor Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 8141 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8145 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8146 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8147 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8148 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 8153 Control Module HVAC: Diagrams Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control Control Module HVAC: Description and Operation Blower Motor Speed Control The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the Electronic Automatic Temperature Control (EATC) module tells the A/C bower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: ^ Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. ^ Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Blower Motor Speed Control > Page 8156 Control Module HVAC: Description and Operation Electronic Climate Control Module The electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: ^ 11 push buttons ^ a blower speed override thumbwheel for manual input ^ a vacuum fluorescent display for displaying set temperature, ambient temperature, function and Diagnostic Trouble Codes (DTCs) ^ an On-Board Diagnostic (OBD) feature to supply the technician with DTCs. These DTCs direct the technician to the inoperative component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control Control Module HVAC: Service and Repair Blower Motor Speed Control REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Remove the kickpad. 3. Disengage the aspirator hose from the bracket. NOTE: Part shown out of vehicle position. 4. Disengage the blower motor speed control mounting bracket from the instrument panel. 5. Disconnect the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8159 6. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8160 Control Module HVAC: Service and Repair Electronic Climate Control Module WITH ELECTRONIC AUTOMATIC TEMPERATURE CONTROL REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the control switch connector. 4. Remove the climate control head. 1 Remove the screws. 2 Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8161 5. Disconnect the climate control head. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Blower Motor Speed Control > Page 8162 Control Module HVAC: Service and Repair Illumination Bulbs REMOVAL 1. Remove the Control assembly. 2. Unsnap the bezel and pivot it open. ^ To replace the general illumination bulbs, unscrew the lamp holder and remove the bulb. ^ To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. NOTE: Place the module upside down on a non-marring surface. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 8166 System Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 8167 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 8173 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Sensor Bracket Bolt 9 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 8177 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: ^ is located in front of the A/C condenser core near the center of the vehicle. ^ contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the Electronic Automatic Temperature Control (EATC) module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 8178 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Remove the pin-type retainers and remove the radiator sight shield. 2. Disconnect the connector. 3. Remove the bolt and remove the ambient air temperature sensor panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 8183 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 8184 Blower Motor Switch: Diagrams Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Description and Operation Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: ^ A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. ^ An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. ^ The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. ^ The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Description and Operation > Page 8188 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. Disconnect the Control switch connector. 3. Remove the steering column cover panel. 4. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Description and Operation > Page 8189 5. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the LH instrument panel finish panel. 6. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 7. Remove the screw. 8. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications Pressure Cut Off Switch 6.8-13.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8194 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Pressure Cut-Off Switch Opens 2896 kPa Approximately A/C Pressure Cut-off Switch Closes 1724 kPa Approximately A/C Cycling Switch Close Maximum 324 kPa A/C Cycling Switch Open Minimum 152 kPa Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. ^ A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. ^ This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. ^ When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. ^ It is not necessary to recover the refrigerant system to remove the A/C pressure cut-off switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 8197 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). ^ The contacts close when the suction pressure rises to 276-324kPa (40-47 psi). ^ When the A/C cycling switch contacts close, the A/C clutch field coil is energized. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to recover the refrigerant system to remove the A/C cycling switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the junction block splash shield. 3. Disconnect the cable ends. 4. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 5. Disconnect the A/C cycling pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8200 6. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Carry out the refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 8201 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. 1 Lubricate the O-ring seal with PAG Compressor Oil F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: ^ is located on the top of the instrument panel. ^ contains a photovoltaic diode that is sensitive to light. ^ has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 8205 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high-pressure service gauge port valve is located on the A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8209 Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure service gauge port valve is located on the A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. The fitting is an integral part of the refrigeration line or component ^ Special couplings are required for both the high side and low side service gauge ports. ^ A new Schrader-type valve core can be installed if the seal leaks. ^ Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation Solar Sensor: Description and Operation The A/C sunload sensor: ^ is located on the top of the instrument panel. ^ contains a photovoltaic diode that is sensitive to light. ^ has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Page 8213 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations > Page 8217 System Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations > Page 8218 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair Vacuum Tester Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 3 mm (0.125 inch) inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (0.375 inch) into the ends of the standard 3 mm (0.125 inch) service vacuum hose section. 6. Shake the service joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. ^ Use the Vacuum Tester or equivalent. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair > Page 8222 Vacuum Tester Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the battery and battery tray. 2. Disconnect the A/C vacuum tank hose from the A/C vacuum reservoir tank and bracket. 3. Remove the A/C vacuum reservoir tank and bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when positioning the A/C vacuum reservoir tank, make sure that the bottom locator and two top tabs align with the battery tray. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8232 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Driver Air Bag Module ......................................................................................................................... ...................................................... 11 Nm (98 Lb-In) Passenger Air Bag Module ............................... ............................................................................................................................................ 9 Nm (80 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications > Page 8236 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications > Page 8237 Air Bag: Service Precautions WARNINGS: - Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications > Page 8238 Air Bag: Description and Operation Driver Air Bag Module Driver Side The driver air bag module: is installed as an assembly. - is mounted in the center of the steering wheel. Passenger Air Bag Module Passenger Side The passenger air bag module: is installed as an assembly. - is mounted in the RH side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Air Bag: Service and Repair Air Bag Disposal Deployed Air Bag 1. Dispose of the deployed air bag modules in the same manner as any other part to be scrapped. WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Undeployed Air Bag Inoperative WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 1. Remove the inoperative driver air bag module or passenger air bag module. NOTE: All inoperative air bag modules have been placed on the Mandatory Return List. All discolored or damaged air bag modules should treated the same as any inoperative live air bag being returned. 2. When installing a new driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. NOTE: When installing a new air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. 3. When installing a new passenger air bag module, record the necessary information and return the inoperative passenger air bag module to Ford Motor Company. Undeployed Air Bag, Scrapped Vehicle Remote Deployment WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the air bag is deployed, hearing protection is required. - Do not place the driver or passenger air bag module with the trim cover or deployment door facing down, as the forces of the deploying air bag can cause it to ricochet and cause personal injury. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 8241 NOTE: The passenger air bag module is shown. The driver air bag module is similar. 1. Remove the passenger air bag module. 2. Cut the two connector wires on the passenger air bag module, and strip 25 mm (1 in) of insulation from the ends of the wires. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and connect one end of each wire to each of the wires on the passenger air bag module. 4. Place the passenger air bag module on a flat surface with the deployment door facing upward in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the passenger air bag module. 6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. Allow at least ten minutes before approaching the deployed air bag to allow for cooling. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 8242 Air Bag: Service and Repair Removal and Installation Driver's Side WARNINGS: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (If equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two back cover plugs from the steering wheel. 3. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 8243 4. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Disconnect the horn switch electrical connector. 3 Remove the driver air bag module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighter the retaining bolts to specification. 2. Prove out the air bag system. Passenger's Side WARNINGS: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 8244 irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not tilt air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the instrument panel relay cover. 3. Disconnect the passenger air bag module. 1 Disconnect the electrical connector. 2 Remove the upper retaining bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 8245 4. Push in the two glove compartment door tabs and position downward. 5. Remove the two lower passenger air bag module retaining bolts. 6. Remove the passenger air bag module. INSTALLATION NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: Make sure to tighten the retaining bolts to specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 8246 1. To install, reverse the removal procedure. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module (RCM) Bracket Bolts ......................................................................................................................................... 12 Nm (9 Lb-Ft) Weld Nut Repair Screw (8 mm) ................................................................................................ ................................................................... 12 Nm (9 Lb-Ft) Grounding Screw (6 mm) ...................... ....................................................................................................................................................... 12 Nm (9 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8251 Air Bag Control Module: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - The tightening torque of the air bag restraint control module retaining bolts is critical for proper system operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8252 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not repaired separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned OFF and then ON), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash a two-digit lamp fault code (LFC). The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the data link connector (DLC), using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and a system fault is detected, the RCM will signal the GEM to activate the audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8253 Air Bag Control Module: Service and Repair REMOVAL WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the scuff plate. 3. Remove the kick panel. 4. Open the glove compartment past its stop. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8254 5. Remove the glove compartment. 1 Remove the three screws. 2 Remove the glove compartment. 6. Disconnect the Restraint Control Module (RCM) electrical connector. 1 Disengage the RCM electrical connector locking clip. 2 Disconnect the RCM electrical connector. 7. Remove the RCM with bracket. 1 Remove the four retaining bolts. 2 Remove the RCM with bracket. NOTE: Upper RCM bracket retaining screws are accessed through the glove compartment opening. INSTALLATION WARNING: The tightening torque of the air bag restraint control module retaining bolts is critical for proper system operation. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8255 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8259 Clockspring Assembly / Spiral Cable: Service Precautions WARNINGS: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8260 Clockspring Assembly / Spiral Cable: Description and Operation The air bag sliding contact: - is mounted on the steering column, behind the steering wheel. - allows uninterrupted electrical connection between the driver air bag module and the Restraints Control Module (RCM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8261 Clockspring Assembly / Spiral Cable: Service and Repair WARNINGS: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module. 3. Remove the steering wheel NOTE: Make sure the wheels are in the straight-ahead position. 4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation. 5. Twist the tilt wheel handle and shank and remove. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8262 6. Remove the upper instrument panel steering column cover. 7. Remove the junction box fuse/relay panel cover. 8. Remove the lower instrument panel steering column cover. 1 Remove the two retaining bolts and disconnect the parking brake release lever. 2 Remove the two retaining bolts and disconnect the hood release lever. 3 Remove the six retaining bolts. 4 Remove the cover. 9. Remove the lower steering column shroud. 1 Remove the three retaining screws. 2 Remove the shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8263 10. Remove the ignition switch lock cylinder. 1 Position the lock cylinder to RUN. 2 Using a suitable tool, push upward on the cylinder release tab while pulling the cylinder outward. 11. Remove the upper steering column shroud. 12. Remove the Passive Anti-Theft System (PATS) transmitter. 1 Remove the retaining screw. 2 Remove the transmitter. 13. Remove the key-in-ignition warning indicator switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8264 14. Disconnect the air bag sliding contact electrical connectors. 1 Separate the electrical connectors from the retaining bracket and disconnect from the harness. 2 Separate the air bag sliding contact wire harness from the clips retaining it to the steering column. 15. Remove the air bag sliding contact. 1 Pry the retaining clips loose. 2 Remove the air bag sliding contact. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws ........................................................................................................................ ......................................................... 12 Nm (9 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8268 Impact Sensor: Service Precautions WARNING: - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8269 Impact Sensor: Service and Repair REMOVAL WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Navigator is shown, Expedition is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator air deflector. 1 Remove the push clips. 2 Remove the radiator air deflector. 3. Disconnect the front crash sensor electrical connector (RH shown, LH similar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8270 4. Remove the front crash sensor. 1 Remove the screws. 2 Remove the air bag sensor. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module Side Air Bag: Service and Repair Driver Side Air Bag Module WARNINGS: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: - The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (If equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two back cover plugs from the steering wheel. 3. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8275 4. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Disconnect the horn switch electrical connector. 3 Remove the driver air bag module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighter the retaining bolts to specification. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8276 Side Air Bag: Service and Repair Passenger Side Air Bag WARNINGS: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not tilt air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8277 3. Disconnect the passenger air bag module. 1 Disconnect the electrical connector. 2 Remove the upper retaining bolt. 4. Push in the two glove compartment door tabs and position downward. 5. Remove the two lower passenger air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8278 6. Remove the passenger air bag module. INSTALLATION NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: Make sure to tighten the retaining bolts to specification. 1. To install, reverse the removal procedure. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions Standby Power Supply: Service Precautions WARNING: To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions > Page 8282 Standby Power Supply: Description and Operation The Restraints Control Module (RCM) includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Testing and Inspection Malfunction Lamp / Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module (RCM) Bracket Bolts ......................................................................................................................................... 12 Nm (9 Lb-Ft) Weld Nut Repair Screw (8 mm) ................................................................................................ ................................................................... 12 Nm (9 Lb-Ft) Grounding Screw (6 mm) ...................... ....................................................................................................................................................... 12 Nm (9 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8290 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8291 Air Bag Control Module: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - The tightening torque of the air bag restraint control module retaining bolts is critical for proper system operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8292 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash. - monitors the air bag Supplemental Restraint System (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not repaired separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned OFF and then ON), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash a two-digit lamp fault code (LFC). The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the data link connector (DLC), using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and a system fault is detected, the RCM will signal the GEM to activate the audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8293 Air Bag Control Module: Service and Repair REMOVAL WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the scuff plate. 3. Remove the kick panel. 4. Open the glove compartment past its stop. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8294 5. Remove the glove compartment. 1 Remove the three screws. 2 Remove the glove compartment. 6. Disconnect the Restraint Control Module (RCM) electrical connector. 1 Disengage the RCM electrical connector locking clip. 2 Disconnect the RCM electrical connector. 7. Remove the RCM with bracket. 1 Remove the four retaining bolts. 2 Remove the RCM with bracket. NOTE: Upper RCM bracket retaining screws are accessed through the glove compartment opening. INSTALLATION WARNING: The tightening torque of the air bag restraint control module retaining bolts is critical for proper system operation. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8295 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8301 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Component Information > Description and Operation Child Restraint: Description and Operation Tether Anchor Hardware A tethered seat can be installed in the front seat; put the tether strap over the seatback and attach it to an anchor bracket. An anchor bracket can be installed on the rear edge of the front seat cushion. The provision (attaching hole) is provided in the rear edge of the seat cushion frame. Tether anchor brackets may also be installed to the floor behind the second row seats. The anchor bracket must be installed using the instructions provided with the kit. Contact your Ford or Lincoln Mercury dealer for a free child safety seat tether anchor kit. Carefully follow the instructions provided with the kit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Safety Belt Anchor Bolt ........................................................................................................................ .......................................... 34-46 Nm (25-33 Lb/Ft) Safety Belt Guide Bolt ........................................ ............................................................................................................................ 34-46 Nm (25-33 Lb/Ft) Safety Belt Guide Nut ................................................................................................................ ..................................................... 34-46 Nm (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection Seat Belt: Service and Repair Cleaning and Inspection 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8310 Seat Belt: Service and Repair Removal and Installation Captain's Chair Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the front floor console. 2. Remove the passenger seat safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8311 4. On manual driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the nut. 3 Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Quad Seat Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8312 Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Position the seat forward. 2. Remove the safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. - Check for proper operation. 40/60 Split Bench Seat, Center and RH Passenger, Front Seat T55 "Torx Plus" Bit Special Tool(s) REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8313 1. Remove the front passenger safety belt. 1 Use T55 "Torx" Bit to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. 40/60 Split Bench Seat, Center and RH Passenger Safety Belt Bolt Bit Special Tool(s) REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8314 1. Remove the safety belt buckle assembly. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the assembly. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. 40/60 Split Bench, Driver Seat Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8315 Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Front Seat Safety Belt Bolt Bit Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8316 Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide. 1 Lift the bolt cover from the bottom. 2 Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. 4. Remove the B-pillar assist handle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8317 1 Remove the two covers. 2 Remove the two screws 3 Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. - Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8318 7. Remove the height adjuster cover. 8. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8319 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Second Row Seat Safety Belt Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8320 2. Remove the C-pillar trim panel. NOTE: Remove upper attachments first, followed by the front lower attachment and the lower rear hook. 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8321 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8322 Seat Belt: Service and Repair Service Procedures Post Collision Inspection 1. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters, if so equipped, child safety seat tether attachments, and attaching hardware should be inspected after any collision. All belt assemblies should be replaced unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. 2. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. See: Testing and Inspection/Component Tests and General Diagnostics Replacement of the Weld Nut and Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If the B- or C- or D-pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance hole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in) diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Safety Belt Tongue Rotated on Belt 1. Fold the safety belt as indicated. 2. Pull the safety belt tongue over the fold in the safety belt. Safety Belt Twisted At the Safety Belt Guide - Outboard Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8323 1. Straighten the twisted belt webbing. 1 Grasp webbing at the safety belt guide. 2 Feed twisted portion of webbing up through safety belt guide. 2. Pull straightened belt downward to check for proper operation. Front, Driver Side Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8324 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. 4. Remove the B-pillar assist handle. 1 Remove the two covers. 2 Remove the two screws. 3 Remove the B-pillar assist handle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8325 5. Position the B-pillar trim panel aside. - Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. 7. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8326 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Before the retractor bolt is installed the retractor bracket should be aligned with the hole in the sheet metal. Second Row Seat, Driver Side Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8327 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the quarter trim panel. 3. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. 4. Remove the center safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8328 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Third Row Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide bolt cover. - Carefully pry out at the bottom. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8329 2. Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. 4. Remove the detachable anchor. - Depress the release button. 5. Remove the rear safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. 6. Remove the detachable anchor tongue trim cover. 1 Remove the bolt. 2 Remove the pushpin. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8330 3 Remove the trim cover. NOTE: Steps six and seven are only necessary if the detachable anchor tongue has to be replaced. 7. Remove the detachable anchor tongue. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the detachable anchor tongue. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8331 D-Ring Installation Kit Special Tool(s) 1. Remove the height adjuster. 2. Use the half-inch drill provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14x 1.5 tap provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8332 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seal the insert keys. NOTE: If the two bolts on the height adjuster are not stripped. If the bolts are stripped, replace the height adjuster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Driver Seat Safely Belt Buckle Bolt ................................................................................................................................................ 34-46 Nm (25-33 Lb/Ft) Driver Seat Safety Belt Buckle Nut ................................................................................................................................................. 34-46 Nm (25-33 Lb/Ft) Passenger Seat Safety Belt Buckle Bolt .......................................................................................................................................... 34-46 Nm (25-33 Lb/Ft) Quad Seat Safety Belt Buckle Bolt ................................................................................................................................................. 34-46 Nm (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair Seat Belt Buckle: Service and Repair Captain's Chair Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the front floor console. 2. Remove the passenger seat safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8338 4. On manual driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the nut. 3 Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8339 Seat Belt Buckle: Service and Repair Quad Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Position the seat forward. 2. Remove the safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. - Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8340 Seat Belt Buckle: Service and Repair 40/60 Split Bench Seat, Center and RH Passenger, Front Seat T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1 Use T55 "Torx" Bit to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8341 Seat Belt Buckle: Service and Repair 40/60 Split Bench Seat, Center and RH Passenger Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the safety belt buckle assembly. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8342 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 8343 Seat Belt Buckle: Service and Repair 40/60 Split Bench, Driver Seat Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through any Ford or Lincoln Mercury dealer parts department at no cost. Safety belt extensions are only available with black webbing. There are two extension assemblies available one for the front seating positions and one for the rear seating positions. They are not interchangeable. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use extension to change the fit of the shoulder belt across the torso. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Safety Belt Height Adjuster ............................................................................................................................................................. 34-46 Nm (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt Seat Belt Height Adjuster: Service and Repair Front Safety Belt Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide. 1 Lift the bolt cover from the bottom. 2 Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8352 4. Remove the B-pillar assist handle. 1 Remove the two covers. 2 Remove the two screws 3 Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. - Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8353 7. Remove the height adjuster cover. 8. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8354 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8355 Seat Belt Height Adjuster: Service and Repair Removal and Installation Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the C-pillar trim panel. NOTE: Remove upper attachments first, followed by the front lower attachment and the lower rear hook. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8356 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8357 Seat Belt Height Adjuster: Service and Repair Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit Special Tool(s) 1. Remove the height adjuster. 2. Use the half-inch drill provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14x 1.5 tap provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 8358 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seal the insert keys. NOTE: If the two bolts on the height adjuster are not stripped. If the bolts are stripped, replace the height adjuster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Safety Belt Retractor Bolt .................................................................................................................... ........................................... 34-46 Nm (25-33 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications > Page 8365 Seat Belt Retractor: Description and Operation Automatic Locking Retraction (ALR) System NOTE: When replacing an Automatic Locking Retraction (ALR) equipped retractor, the retractor should be checked to make sure it is not in the ALR mode after installation. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the ALR system. This system is used when installing a child safety seat in an outboard seating position or when a tight lap/shoulder belt is desired by the occupant. The ALR system is automatically engaged when the webbing is fully extracted from the retractor. As the webbing is retracted back onto the spool, an audible clicking sound is made indicating the retractor is in the ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. The ALR mode is disengaged when the audible clicking sound ceases and the webbing is free to move in or out of the retractor indicating a normal mode of operation. The automatic locking mode must be used when installing a child safety seat in the front passenger and rear outboard passenger seating positions where dual locking mode retractors are provided. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side Seat Belt Retractor: Service and Repair Front - Driver Side Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8368 4. Remove the B-pillar assist handle. 1 Remove the two covers. 2 Remove the two screws. 3 Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. - Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8369 7. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. NOTE: Before the retractor bolt is installed the retractor bracket should be aligned with the hole in the sheet metal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8370 Seat Belt Retractor: Service and Repair Second Row Seat - Driver Side Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the quarter trim panel. 3. Use Safety Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8371 4. Remove the center safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8372 Seat Belt Retractor: Service and Repair Third Row Seat Safety Belt Safety Belt Bolt Bit Special Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide bolt cover. - Carefully pry out at the bottom. 2. Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8373 4. Remove the detachable anchor. - Depress the release button. 5. Remove the rear safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. 6. Remove the detachable anchor tongue trim cover. 1 Remove the bolt. 2 Remove the pushpin. 3 Remove the trim cover. NOTE: Steps six and seven are only necessary if the detachable anchor tongue has to be replaced. 7. Remove the detachable anchor tongue. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front - Driver Side > Page 8374 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the detachable anchor tongue. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws ........................................................................................................................ ......................................................... 12 Nm (9 Lb-Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8379 Impact Sensor: Service Precautions WARNING: - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8380 Impact Sensor: Service and Repair REMOVAL WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Navigator is shown, Expedition is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator air deflector. 1 Remove the push clips. 2 Remove the radiator air deflector. 3. Disconnect the front crash sensor electrical connector (RH shown, LH similar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8381 4. Remove the front crash sensor. 1 Remove the screws. 2 Remove the air bag sensor. INSTALLATION 1. Follow the removal procedure in reverse order. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8387 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8388 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8389 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair REMOVAL 1. On 4x4 vehicles, remove the front wheel opening moulding. 1 Remove the pin-type retainer. 2 Remove the screws. 3 Carefully pull the wheel opening moulding to release the nine clips and remove the front wheel opening moulding. 2. Remove the inner fender splash shield. 1 Remove the screws. 2 Pull the inner fender splash shield to release the clips. 3. Disconnect the radio antenna lead-in cable from the antenna base. 4. Remove the audio unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 8395 5. Push the radio antenna lead- in cable into the passenger compartment. 1 Disconnect the antenna clip from the sheet metal. 2 Push the grommet into the passenger compartment. 3 Push the radio antenna lead-in cable into the passenger compartment. 6. Remove the radio antenna lead-in cable. 1 Disconnect the three cable locators from the lower metal instrument panel (I/P) channel. 2 Remove the radio antenna lead-in cable from under the instrument panel. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 8396 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8401 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8404 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8405 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8406 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Erase All Key Codes and Program Two Keys Alarm System Transmitter: Service and Repair Erase All Key Codes and Program Two Keys SPECIAL SERVICE TOOLS NOTE ^ This procedure is used when a customer needs keys programmed into the system and does not have two programmed ignition keys available. This procedure is also useful when programmed ignition key(s) have been lost or the ignition switch assembly has been replaced, and it is desired to erase key(s) from the passive anti-theft system (PATS) memory. ^ This procedure will erase all programmed ignition keys from the vehicle memory and the vehicle will not start until two keys have been reprogrammed to the vehicle. ^ Two PATS encoded keys with the correct mechanical cut must be available to perform this procedure. One or both of them may be the customers original keys. ^ If additional keys are to be programmed, refer to Key Programming -Program a Key Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, then instruct the customer to refer to the Owners Guide under the 'Programming Spare [SecuriLock(R) (North America), Safeguard(R) (U.K.) or PATS for all other markets] Keys Procedure" for instructions on programming the remaining keys. 1. Turn lie ignition switch from OFF to RUN. 2. Enter New Generation STAR/Service Bay Diagnostic System (NGS/SBDS). Follow the SECURITY ACCESS PROCEDURE to obtain security access. 3. From NGS/SBDS menu, select IGNITION KEY CODE ERASE. 4. Turn the ignition switch to OFF and disconnect NGS. NOTE: Do NOT select any additional commands from this menu. 5. Insert the first encoded key into the ignition lock cylinder and turn the switch to RUN for three seconds. 6. Insert the second encoded key into the ignition lock cylinder and turn the switch to RUN for three seconds. 7. The vehicle should now start with both ignition keys. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Erase All Key Codes and Program Two Keys > Page 8411 Alarm System Transmitter: Service and Repair Program A Key Using Two Programmed Keys SPECIAL SERVICE TOOLS NOTE ^ This procedure only works if two or more programmed ignition keys are available and it is desired to program additional key(s). If two keys are not available, follow the procedure in Key Programming-Erase All Key Codes and Program Two Keys. ^ PID SPARE__KY must be enabled for this procedure to operate. If this Parameter Identification (PID) Index is not enabled, follow the security access procedure and select Spare Key Programming Switch: Enabled. ^ If the programming procedure is successful, the new key(s) will start the vehicle and the THEFT INDICATOR will illuminate for approximately three seconds. ^ If the programming procedure is not successful, the new key(s) will not start the vehicle and the THEFT INDICATOR will flash. If the programming procedure was not successful, repeat the key programming procedure from Step 1. If the failure repeats, check Circuit 729 (RD/WH) (not at all times) in instrument cluster for proper battery voltage. Repair the circuit if voltage is not present. For additional information, refer to Diagnosis and Testing to review Diagnostic Trouble Codes (DTCs) and perform pinpoint tests as required. ^ A maximum of eight ignition keys can be programmed to a Passive Anti-Theft system (PATS) equipped Vehicle. Use PID NUMKEYS to determine how many keys are programmed to the vehicle. ^ If the steps are not performed, the programming procedure will end. ^ Ignition keys must have correct mechanical key cut for the vehicle and must be a PATS encoded key. 1. Insert the first programmed ignition key into the ignition lock cylinder and turn the ignition switch from OFF to RUN (maintain the ignition switch in RUN for one second). 2. Turn the ignition switch to OFF and remove the first key from the ignition lock cylinder. 3. Within five seconds of turning the ignition switch to OFF, insert the second programmed ignition key into the ignition lock cylinder and turn the ignition switch from OFF to RUN (maintain the ignition switch in RUN for one second). 4. Turn the ignition switch to OFF and remove the second key from the ignition lock cylinder. 5. Within 10 seconds of turning the ignition lock cylinder to OFF, insert the unprogrammed ignition key (new key) into the ignition lock cylinder and turn the ignition switch from OFF to RUN (maintain the ignition switch in RUN for 1 second). 6. If it is desired to program additional key(s), repeat the key programming procedure from the beginning. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Erase All Key Codes and Program Two Keys > Page 8412 Alarm System Transmitter: Service and Repair Spare Key Programming Switch NOTE ^ The spare key programming switch is a New Generation STAR/Service Bay Diagnostic System (NGS/SBDS) programmable switch that provides the capability to enable/disable the spare key programming procedure. This procedure is in the Owners Guide spare key programming procedure or under the procedure named Key Programming-Program a Key Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. ^ The spare key programming switch state can be viewed by instrument cluster PID SPARE__KY. 1. Insert a programmed ignition key into the ignition lock cylinder and turn the ignition switch to RUN. 2. Enter NGS/SBDS. Follow the SECURITY ACCESS PROCEDURE. 3. From NGS/SBDS menu, select SPARE KEY PROGRAMMING SWITCH selection to the desired setting: Spare key programming procedure is accessible. Spare key programming procedure is not accessible. NOTE: The default setting on delivery of all new vehicles is . Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Erase All Key Codes and Program Two Keys > Page 8413 Alarm System Transmitter: Service and Repair With Diagnostic Equipment NOTE ^ This procedure is used when a customer needs to have an additional key programmed into the vehicle without erasing stored key codes, but does not have two programmed keys available. This procedure is also useful when attempting to determine if an ignition key is defective, as a new key can be installed without erasing keys or without having two programmed keys available. ^ Before programming, the new key must have the correct mechanical cut for the ignition lock. ^ If eight keys are already programmed, this procedure will not allow any further ignition keys to be programmed without erasing all stored key codes first. The number of keys programmed into the system can be determined using the PID NUMKEYS. 1. Turn the ignition switch from the OFF position to the RUN position using the new, unprogrammed ignition key. 2. Enter NGS/SBD'S using the Ford Service Function (FSF) card and enter the appropriate instrument cluster. Follow Security Access to obtain security access. 3. From the NGS/SBDS menu Select: IGNITION KEY CODE PROGRAM. 4. Turn the ignition switch to the OFF position and disconnect NGS/SBDS. 5. Attempt to start the engine with the new ignition key. The vehicle engine should start and run normally. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8419 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8420 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8421 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the driver door trim panel. 2. Remove the keyless entry keypad. 1. Remove the screw. 2. Remove the speed ruts. 3. Remove the keyless entry keypad. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications Remote Anti-Theft Personality Module Nuts 62 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 8425 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 8426 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 8427 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the remote anti-theft personality module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: The antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the NGS Tester into the new module. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair PROGRAMMING NOTE: ^ The keyless entry remote transmitters are reprogrammable and must be set at the same time. ^ To program (or reprogram) the keyless entry remote transmitters into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN 8 times within 10 seconds, ending in RUN. If the RAP module has successfully entered the program mode, it will lock and then unlock all doors. 2. Press any button on the keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Diagnosis and Testing. See: Testing and Inspection 4. Turn the ignition switch to the OFF position, or wait up to five minutes after Step 2, to exit the program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Testing and Inspection Security Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions Cellular Phone: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 Cellular Phone: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 Cellular Phone: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 Diagram 135-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Page 8453 Cellular Phone: Description and Operation Portable Cellular Phone Features The low cost portable cellular phone system is available only with the P100i audio unit and has the following features: ^ hands-free operation ^ radio muting while phone is in use ^ radio displays the phone number, signal strength, and call timer ^ radio can be used to dial stored numbers and adjust hands-free operation volume Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis Cellular Phone: Flow of Diagnosis INSPECTION AND VERIFICATION NOTE ^ Dropped calls, bad connections, noisy audio, problems in certain geographic areas, problems at the edge of coverage areas, same time-place each day or under bridges, tunnels, etc., usually indicate a system or cellular carrier concern and are not the fault of the phone itself. ^ A customer initial call must be made from their home coverage area for proper activation of the Ford Cellular System. There might be a slight delay in activation after leaving the dealership from initial delivery. ^ The audio system does not operate when the portable cellular phone is in use because the audio-mute feature will mute the audio system when a call is placed or received. If there is a concern making calls on the portable convertible phone while it is connected to the vehicle, check the following information first: 1. Make sure the portable convertible phone is turned ON. With the power button ON, the system should be on while the ignition switch is in ACC or RUN. 2. Make sure the customer is calling within the coverage area. No SVC will appear in the display if the customer is calling from outside the coverage area. 3. Check to see if the Roam indicator is on. If so, follow the roaming instructions in the User's Guide 4. Check to see if the display reads Locked. If so, press Clr and enter the customer three-digit unlock code. 5. Make sure the portable cellular phone is securely connected to the coil cord and seated in the holder. 6. Check the coil cord connections in the console. 7. Check the portable cellular phone antenna and Portable Support Electronics (PSE) module connections. 8. Check the portable cellular phone system registration. Also, check to make sure that the portable cellular phone is correctly programmed. Incorrect programming can result in single system scanning, loss of speed dialing, loss of hands-free audio, loss of auto redial, loss of dial tone multi- frequency tones, and the loss of other keypad/portable cellular phone functions. 9. Check the customer account status with the cellular carrier. If the customer concern is still present, follow these steps to diagnose the concern: 10. Verify the customer concern by operating the portable cellular phone system to duplicate the condition. 11. Inspect to determine if one of the following mechanical or electrical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged portable cellular phone ^ Damaged microphone ^ Damaged PSE module ^ Damaged portable cellular phone holder ^ Damaged coil cord Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (10 A) ^ Blown CJB Fuse 38 (10 A) ^ Damaged, loose, or corroded connectors 12. If inspection reveals obvious concerns which can be readily identified, repair as necessary. 13. If the cause of the fault is not visually evident, proceed to diagnose the portable cellular phone system/audio control module (ACM) by: ^ Entering the New Generation STAR (NGS) Tester Diagnostics See: Reading and Clearing Diagnostic Trouble Codes or ^ Entering ACM Self-Diagnostic Mode. See: Diagnostic Trouble Code Descriptions/ACM Self-Diagnostic Mode Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8456 Cellular Phone: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION NOTE ^ Dropped calls, bad connections, noisy audio, problems in certain geographic areas, problems at the edge of coverage areas, same time-place each day or under bridges, tunnels, etc., usually indicate a system or cellular carrier concern and are not the fault of the phone itself. ^ A customer initial call must be made from their home coverage area for proper activation of the Ford Cellular System. There might be a slight delay in activation after leaving the dealership from initial delivery. ^ The audio system does not operate when the portable cellular phone is in use because the audio-mute feature will mute the audio system when a call is placed or received. If there is a concern making calls on the portable convertible phone while it is connected to the vehicle, check the following information first: 1. Make sure the portable convertible phone is turned ON. With the power button ON, the system should be on while the ignition switch is in ACC or RUN. 2. Make sure the customer is calling within the coverage area. No SVC will appear in the display if the customer is calling from outside the coverage area. 3. Check to see if the Roam indicator is on. If so, follow the roaming instructions in the User's Guide 4. Check to see if the display reads Locked. If so, press Clr and enter the customer three-digit unlock code. 5. Make sure the portable cellular phone is securely connected to the coil cord and seated in the holder. 6. Check the coil cord connections in the console. 7. Check the portable cellular phone antenna and Portable Support Electronics (PSE) module connections. 8. Check the portable cellular phone system registration. Also, check to make sure that the portable cellular phone is correctly programmed. Incorrect programming can result in single system scanning, loss of speed dialing, loss of hands-free audio, loss of auto redial, loss of dial tone multi- frequency tones, and the loss of other keypad/portable cellular phone functions. 9. Check the customer account status with the cellular carrier. If the customer concern is still present, follow these steps to diagnose the concern: 10. Verify the customer concern by operating the portable cellular phone system to duplicate the condition. 11. Inspect to determine if one of the following mechanical or electrical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged portable cellular phone ^ Damaged microphone ^ Damaged PSE module ^ Damaged portable cellular phone holder ^ Damaged coil cord Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (10 A) ^ Blown CJB Fuse 38 (10 A) ^ Damaged, loose, or corroded connectors 12. If inspection reveals obvious concerns which can be readily identified, repair as necessary. 13. If the cause of the fault is not visually evident, proceed to diagnose the portable cellular phone system/audio control module (ACM) by: ^ Entering the New Generation STAR (NGS) Tester Diagnostics See: Reading and Clearing Diagnostic Trouble Codes or ^ Entering ACM Self-Diagnostic Mode. See: Diagnostic Trouble Code Descriptions/ACM Self-Diagnostic Mode Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8457 Cellular Phone: Reading and Clearing Diagnostic Trouble Codes 1. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 2. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. NOTE ^ The ACM must be in AM, FM1, or FM2 mode to enter NGS tester diagnostics. ^ The portable cellular phone system is diagnosed through the ACM. 3. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O - ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for audio control module (ACM), go to Pinpoint Test A. See: Pinpoint Tests/A: No Communication With Audio Control Module ^ SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the ACM. 4. If the DTCs retrieved are related to the concern, go to the ACM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/ACM Diagnostic Trouble Code Index 5. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures/Diagnosis by Symptom Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8458 Cellular Phone: Diagnostic Trouble Code Descriptions Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8459 Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8460 ACM Self-Diagnostic Mode NOTE: To enter the Speaker Walk-Around Test or ACM self-diagnostic mode, the ACM must be turned on and in radio tuner mode (AM/FM). ACM self-diagnostic mode can only be entered while in the Speaker Walk-Around Test. 1. To enter the Speaker Walk-Around Test, press the ACM Preset Buttons 3 and 6 simultaneously. 2. The Speaker Walk-Around Test stops at each speaker and applies a different tone to each speaker for about 1-2 seconds. Each speaker is tested and displayed on the ACM in the following sequence: RF, LF, LR, RR, SUBWOOFER I, SUBWOOFER II. 3. The Speaker Walk-Around Test automatically continues and tests: ^ the antenna and displays ANTENNA II, for five seconds. ^ for a speaker short. if a short is present, SPKR SHORT will be displayed. ^ for the CD/DJ. The ACM display will show NO DJ if not present. The Speaker Walk-Around Test will end and the ACM will return to its previous setting. 4. ACM self-diagnostic mode has five tests available: ^ Preset button 1 = Audio internal/external SELF TEST. If SELF FAIL is displayed, press TUNE > to scroll view the DTCs stored. Refer to the ACM Diagnostic Trouble Codes (DTC) Index. See: ACM Diagnostic Trouble Code Index If the system is OK, SELF PASS is displayed. ^ Preset button 2= View/Clear continuous diagnostic trouble codes (DTCs). NO DTCS is displayed if no DTCs are retrieved. If DTCS FOUND is displayed, press TUNE > button to view the DTCs retrieved. Refer to the ACM Diagnostic Trouble Codes (DTC) Index. See: ACM Diagnostic Trouble Code Index To clear all DTCs, press the EJECT button. DTCS CLEAR will be displayed. ^ Preset button 3 = SIGNAL TEST. This test measures the average strength at the current tuner setting. ^ Preset button 4 = Software configuration level. This test queries each radio system controller for the software configuration level. SOFT LEVELS will be displayed upon completion of the query. Press TUNE > to scroll view the software configuration version level. ^ Preset button 5= DISPLAY TEST. This test will light all the ACM display segments for five seconds, then turn all segments off. When the test is complete, DISPLAY TEST is displayed on the bezel. 5. To enter these tests, press the preset button desired while in the Speaker Walk-Around Test. This will abort the Speaker Walk-Around Test and start the selected test. 6. To exit ACM self-diagnostic mode, turn the ignition switch or ACM OFF. 7. If the concern remains and the fault is not detected, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures/Diagnosis by Symptom Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8461 Cellular Phone: Testing and Inspection Flow of Diagnosis INSPECTION AND VERIFICATION NOTE ^ Dropped calls, bad connections, noisy audio, problems in certain geographic areas, problems at the edge of coverage areas, same time-place each day or under bridges, tunnels, etc., usually indicate a system or cellular carrier concern and are not the fault of the phone itself. ^ A customer initial call must be made from their home coverage area for proper activation of the Ford Cellular System. There might be a slight delay in activation after leaving the dealership from initial delivery. ^ The audio system does not operate when the portable cellular phone is in use because the audio-mute feature will mute the audio system when a call is placed or received. If there is a concern making calls on the portable convertible phone while it is connected to the vehicle, check the following information first: 1. Make sure the portable convertible phone is turned ON. With the power button ON, the system should be on while the ignition switch is in ACC or RUN. 2. Make sure the customer is calling within the coverage area. No SVC will appear in the display if the customer is calling from outside the coverage area. 3. Check to see if the Roam indicator is on. If so, follow the roaming instructions in the User's Guide 4. Check to see if the display reads Locked. If so, press Clr and enter the customer three-digit unlock code. 5. Make sure the portable cellular phone is securely connected to the coil cord and seated in the holder. 6. Check the coil cord connections in the console. 7. Check the portable cellular phone antenna and Portable Support Electronics (PSE) module connections. 8. Check the portable cellular phone system registration. Also, check to make sure that the portable cellular phone is correctly programmed. Incorrect programming can result in single system scanning, loss of speed dialing, loss of hands-free audio, loss of auto redial, loss of dial tone multi- frequency tones, and the loss of other keypad/portable cellular phone functions. 9. Check the customer account status with the cellular carrier. If the customer concern is still present, follow these steps to diagnose the concern: 10. Verify the customer concern by operating the portable cellular phone system to duplicate the condition. 11. Inspect to determine if one of the following mechanical or electrical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged portable cellular phone ^ Damaged microphone ^ Damaged PSE module ^ Damaged portable cellular phone holder ^ Damaged coil cord Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (10 A) ^ Blown CJB Fuse 38 (10 A) ^ Damaged, loose, or corroded connectors 12. If inspection reveals obvious concerns which can be readily identified, repair as necessary. 13. If the cause of the fault is not visually evident, proceed to diagnose the portable cellular phone system/audio control module (ACM) by: ^ Entering the New Generation STAR (NGS) Tester Diagnostics See: Reading and Clearing Diagnostic Trouble Codes or ^ Entering ACM Self-Diagnostic Mode. See: Diagnostic Trouble Code Descriptions/ACM Self-Diagnostic Mode Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION NOTE ^ Dropped calls, bad connections, noisy audio, problems in certain geographic areas, problems at the edge of coverage areas, same time-place each day or under bridges, tunnels, etc., usually indicate a system or cellular carrier concern and are not the fault of the phone itself. ^ A customer initial call must be made from their home coverage area for proper activation of the Ford Cellular System. There might be a slight delay in activation after leaving the dealership from initial delivery. ^ The audio system does not operate when the portable cellular phone is in use because the audio-mute feature will mute the audio system when a call is placed or received. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8462 If there is a concern making calls on the portable convertible phone while it is connected to the vehicle, check the following information first: 1. Make sure the portable convertible phone is turned ON. With the power button ON, the system should be on while the ignition switch is in ACC or RUN. 2. Make sure the customer is calling within the coverage area. No SVC will appear in the display if the customer is calling from outside the coverage area. 3. Check to see if the Roam indicator is on. If so, follow the roaming instructions in the User's Guide 4. Check to see if the display reads Locked. If so, press Clr and enter the customer three-digit unlock code. 5. Make sure the portable cellular phone is securely connected to the coil cord and seated in the holder. 6. Check the coil cord connections in the console. 7. Check the portable cellular phone antenna and Portable Support Electronics (PSE) module connections. 8. Check the portable cellular phone system registration. Also, check to make sure that the portable cellular phone is correctly programmed. Incorrect programming can result in single system scanning, loss of speed dialing, loss of hands-free audio, loss of auto redial, loss of dial tone multi- frequency tones, and the loss of other keypad/portable cellular phone functions. 9. Check the customer account status with the cellular carrier. If the customer concern is still present, follow these steps to diagnose the concern: 10. Verify the customer concern by operating the portable cellular phone system to duplicate the condition. 11. Inspect to determine if one of the following mechanical or electrical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged portable cellular phone ^ Damaged microphone ^ Damaged PSE module ^ Damaged portable cellular phone holder ^ Damaged coil cord Electrical ^ Blown Central Junction Box (CJB) Fuse 4 (10 A) ^ Blown CJB Fuse 38 (10 A) ^ Damaged, loose, or corroded connectors 12. If inspection reveals obvious concerns which can be readily identified, repair as necessary. 13. If the cause of the fault is not visually evident, proceed to diagnose the portable cellular phone system/audio control module (ACM) by: ^ Entering the New Generation STAR (NGS) Tester Diagnostics See: Reading and Clearing Diagnostic Trouble Codes or ^ Entering ACM Self-Diagnostic Mode. See: Diagnostic Trouble Code Descriptions/ACM Self-Diagnostic Mode Reading and Clearing Diagnostic Trouble Codes 1. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 2. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. NOTE ^ The ACM must be in AM, FM1, or FM2 mode to enter NGS tester diagnostics. ^ The portable cellular phone system is diagnosed through the ACM. 3. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT7O - ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for audio control module (ACM), go to Pinpoint Test A. See: Pinpoint Tests/A: No Communication With Audio Control Module ^ SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the ACM. 4. If the DTCs retrieved are related to the concern, go to the ACM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/ACM Diagnostic Trouble Code Index 5. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures/Diagnosis by Symptom Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8464 Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8465 ACM Self-Diagnostic Mode NOTE: To enter the Speaker Walk-Around Test or ACM self-diagnostic mode, the ACM must be turned on and in radio tuner mode (AM/FM). ACM self-diagnostic mode can only be entered while in the Speaker Walk-Around Test. 1. To enter the Speaker Walk-Around Test, press the ACM Preset Buttons 3 and 6 simultaneously. 2. The Speaker Walk-Around Test stops at each speaker and applies a different tone to each speaker for about 1-2 seconds. Each speaker is tested and displayed on the ACM in the following sequence: RF, LF, LR, RR, SUBWOOFER I, SUBWOOFER II. 3. The Speaker Walk-Around Test automatically continues and tests: ^ the antenna and displays ANTENNA II, for five seconds. ^ for a speaker short. if a short is present, SPKR SHORT will be displayed. ^ for the CD/DJ. The ACM display will show NO DJ if not present. The Speaker Walk-Around Test will end and the ACM will return to its previous setting. 4. ACM self-diagnostic mode has five tests available: ^ Preset button 1 = Audio internal/external SELF TEST. If SELF FAIL is displayed, press TUNE > to scroll view the DTCs stored. Refer to the ACM Diagnostic Trouble Codes (DTC) Index. See: Diagnostic Trouble Code Descriptions/ACM Diagnostic Trouble Code Index If the system is OK, SELF PASS is displayed. ^ Preset button 2= View/Clear continuous diagnostic trouble codes (DTCs). NO DTCS is displayed if no DTCs are retrieved. If DTCS FOUND is displayed, press TUNE > button to view the DTCs retrieved. Refer to the ACM Diagnostic Trouble Codes (DTC) Index. See: Diagnostic Trouble Code Descriptions/ACM Diagnostic Trouble Code Index To clear all DTCs, press the EJECT button. DTCS CLEAR will be displayed. ^ Preset button 3 = SIGNAL TEST. This test measures the average strength at the current tuner setting. ^ Preset button 4 = Software configuration level. This test queries each radio system controller for the software configuration level. SOFT LEVELS will be displayed upon completion of the query. Press TUNE > to scroll view the software configuration version level. ^ Preset button 5= DISPLAY TEST. This test will light all the ACM display segments for five seconds, then turn all segments off. When the test is complete, DISPLAY TEST is displayed on the bezel. 5. To enter these tests, press the preset button desired while in the Speaker Walk-Around Test. This will abort the Speaker Walk-Around Test and start the selected test. 6. To exit ACM self-diagnostic mode, turn the ignition switch or ACM OFF. 7. If the concern remains and the fault is not detected, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures/Diagnosis by Symptom Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8466 System/Carrier Concerns Dropped calls, bad connections, noisy audio, and other intermittent symptoms usually indicate a system or cellular carrier concern, and are not the fault of the phone itself. Such symptoms may occur in situations such as the following: ^ In certain geographic areas (for example areas of excessive foliage or hills) or at the edge of coverage areas. ^ At the same place each day. ^ At the same time each day. ^ Under bridges, tunnels, in lower freeways, and in congested downtown areas. If the customer phone exhibits any of the above symptoms or symptoms occur under the above conditions, the customer or the dealer should contact customer assistance at their particular cellular provider/carrier or call the 1-800 assistance number provided in the Ford Cellular System Dealer Kit. Other Possible Concerns 1. If, for some reason, the customer's electronic serial number was incorrectly recorded in the carrier switch, the phone will not work. Call the 1-800 number in your dealer kit to check the electronic serial number. 2. A customer initial call must be made in his/her home coverage area for correct activation of the Ford Cellular System. 3. A customer may have to wait until after 24 hours of the coverage activation before making a call from outside of his/her home coverage area or the phone might be reported stolen and coverage stopped. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8467 4. There may be a slight delay in activation after leaving the dealership from initial delivery. If, after checking these possibilities, the phone still does not function, do not attempt to repair the phone. Call the cellular distributor, Audiotronics, at 1-800-755-4161. Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8468 In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A1 - A3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8469 B1 B2 C: Phone Does Not Power Up Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8470 C1 - C2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8471 C3 - C4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8472 C5 - C6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8473 D1 - D3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8474 D4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8475 E1 - E3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8476 F1 - F3 G: Cellular Phone Microphone Not Operating Correctly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8477 G1 - G2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8478 G3 - G4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8479 G5 - G6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8480 H1 - H2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8481 H3 I1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8482 J1 - J3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8483 K1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8484 K2 - K3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module Cellular Phone: Service and Repair Portable Support Electronics (PSE) Module REMOVAL 1. Remove the front floor console. 2. Remove the Portable Support Electronics (PSE) module and bracket assembly. 1 Disconnect the PSE electrical connector. 2 Remove the screws. 3 Remove the PSE module and bracket assembly. 3. Remove the PSE module. 1 Remove the screws. 2 Remove the PSE module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module > Page 8487 Cellular Phone: Service and Repair Microphone REMOVAL 1. Remove the air bag sliding contact. 2. Remove the cellular phone microphone from the air bag sliding contact. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module > Page 8488 Cellular Phone: Service and Repair Antenna REMOVAL 1. Disconnect the vehicle cellular phone antenna base cable. 2. Cut the two-way tape holding the vehicle cellular phone antenna base to the glass. ^ Remove the vehicle cellular phone antenna base. CAUTION: To avoid damage to the glass, do not pry on the vehicle cellular phone antenna base when removing. INSTALLATION 1. Install the two-way tape on the vehicle cellular phone antenna base. NOTE: Use a suitable glass cleaner to thoroughly clean the glass and vehicle cellular phone antenna base contact surfaces. 2. Attach the vehicle cellular phone antenna base to the glass. NOTE: The inside and outside vehicle cellular phone antenna bases must be carefully and accurately aligned with each other. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module > Page 8489 3. Connect the vehicle cellular phone antenna base cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module > Page 8490 Cellular Phone: Service and Repair Handset - Cord REMOVAL 1. Remove the cellular phone holder. 1 Remove the screws. 2 Remove the cellular phone holder. 2. Remove the center console lid. 1 Remove the screws. 2 Remove the center console lid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module > Page 8491 3. Disconnect the center console rear panel. 1 Remove the screws. 2 Disengage the clips. ^ Disconnect the connectors and temperature door link (if equipped). 4. Remove the rear A/C and heater duct. 1 Remove the screws. 2 Remove the rear A/C and heater duct. 5. Disconnect the antenna cable and the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Portable Support Electronics (PSE) Module > Page 8492 6. Remove the handset cord. ^ Disconnect the cord from the handset. 1 Remove the rubber grommet. 2 Pull the handset cord through the opening. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Driver Information/Message Center Driver/Vehicle Information Display: Description and Operation Driver Information/Message Center The message center is located in the overhead console and consists of the following components: ^ Powertrain Control Module (PCM) ^ compass sensor module ^ message center ^ fuel level sensor and pump ^ Output Shaft Speed (OSS) sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Driver Information/Message Center > Page 8497 Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It Work?) Average (AVG) Fuel Economy - Resetting NOTE: Only the AVG fuel economy can be reset. DTE and INST displays cannot be reset. The AVG fuel economy display is resettable. To reset, the ignition switch must be in the RUN position (with or without the engine running) and the message center must be in the AVG fuel economy display mode. Press and release the MODE and E/M buttons simultaneously. If the vehicle is parked while resetting, the AVG fuel economy will display 0.0 (English mode) or 99.9 (metric mode). If the vehicle is in motion, the AVG fuel economy will display the current INST fuel economy (English mode or metric mode). Information and Message Center NOTE ^ The Distance To Empty (DTE) display may be inaccurate if the vehicle is started while parked on an incline. ^ Fuel fills of less than 22.7 liters (6 gallons) may not be detected by the message center. ^ The Instantaneous (INST) fuel economy feature is only available on early production vehicles. The message center uses inputs from the fuel level sensor and pump, the compass sensor module and the Powertrain Control Module (PCM). The input from the PCM is the vehicle speed signal. The PCM gets the vehicle speed signal from the Output Shaft Speed (OSS) sensor. From those inputs, the message center displays: ^ compass direction. ^ DTE. ^ average (AVG) fuel economy. ^ INST fuel economy (if equipped). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged overhead trip computer ^ Damaged OSS sensor ^ Damaged compass sensor module or loose mounting ^ PCM Electrical ^ Blown central junction box (CJB) fuse 6: Fuse 2 (5 A) - Fuse 6 (5 A) ^ Damaged wiring harness ^ Loose or corroded connections 3. If the fault is not visually evident, perform the Message Center Self-Test. See: Component Tests and General Diagnostics Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8500 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8501 Driver/Vehicle Information Display: Pinpoint Tests A: The Compass Is Inaccurate A1 - A3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8502 A4 - A5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8503 A6 - A7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8504 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8505 C1 D: Dist. To Empty/Av/Instant Fuel Economy Inop/Incorrect Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8506 D1 - D2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8507 D3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8508 D4 - D5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8509 E1 F1 Icons Used With Pinpoint Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8510 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8511 Driver/Vehicle Information Display: Component Tests and General Diagnostics Message Center Message Center Self-Test (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8512 Message Center Self-Test (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8513 Message Center Self-Test (Part 3 Of 3) 1. The Message Center Self-Test can be entered by pressing the E/M and MODE buttons simultaneously while starting the vehicle. After entering the Message Center Self-Test release the E/M and MODE buttons. Advancing to a desired test is accomplished by pressing the MODE button. To abort the Message Center Self-Test, turn the ignition switch to the OFF position. NOTE: Vehicle doors must be closed and the engine must be running while in the Message Center Self-Test mode to receive accurate data. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Zone Adjustment Driver/Vehicle Information Display: Adjustments Compass Zone Adjustment 1. The zone setting is factory pre-set to Zone 8. Check the Compass Calibration Zone map to verify the correct compass zone setting for your geographic location. 2. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Gently press the switch for one to two seconds until ZONE and the current zone setting are displayed. 3. Release the switch. 4. Press the switch repeatedly to cycle the display through all possible zone settings. Stop cycling when the correct zone setting for your location is displayed. 5. Release the switch to exit the zone setting mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Zone Adjustment > Page 8516 Driver/Vehicle Information Display: Adjustments Calibration Adjustment 1. For optimum calibration, turn off all non-essential electrical accessories (rear window defrost, heater/air conditioning, map lamps, wipers, etc.) and make sure all doors are shut. 2. Drive to an open, level area away from large metallic objects or structures and high voltage lines. 3. Insert an appropriate-diameter rod, preferably non- metallic, into the switch access hole underneath the compass module. Press gently for two to four seconds until CAL and a direction are displayed. 4. Release the switch and drive slowly in a circle until CAL disappears from the display (about two to three circles). 5. The compass is now calibrated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Removal and Installation Driver/Vehicle Information Display: Service and Repair Removal and Installation MESSAGE CENTER ASSEMBLY REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console and pull down to remove the console. 3. Disconnect the electrical connectors. 4. Remove the message center. 1 Depress the lock tab underneath the in-line electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Removal and Installation > Page 8519 2 Remove the in-line connector. 3 Remove the screws. 4 Remove the message center. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Removal and Installation > Page 8520 Driver/Vehicle Information Display: Service and Repair Vehicle Demagnetizing 1. CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a clothe over the vehicle's roof to protect the vehicle's surface if contact occurs. Make sure the clothe covers the front third and the entire width of the roof. NOTE ^ The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. ^ To demagnetize, use a constant circular motion over the vehicle's roof. Do not turn off the demagnetizer while sweeping the vehicle's roof to prevent remagnetizing ferrous materials contained in the vehicle. ^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle's surface. 2. Demagnetize the front third of the vehicle's roof. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 3. Demagnetize the inside rear view mirror mounting pad. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 3 Turn the demagnetizer off. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm(1 in). 4. Perform the Compass Zone Adjustment procedure. See: Adjustments/Compass Zone Adjustment 5. Perform the Calibration Adjustment procedure. See: Adjustments/Calibration Adjustment Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8521 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Locations Multifunction Electronic Control Module: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Locations > Page 8525 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Multifunction Electronic Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 Multifunction Electronic Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 Multifunction Electronic Control Module: Electrical Diagrams Diagram 59-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 Diagram 59-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8546 Diagram 59-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8547 Diagram 59-4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8548 Diagram 59-5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8549 Multifunction Electronic Control Module: Description and Operation The multi function modules consist of the following: ^ Generic Electronic Module (GEM) The Generic Electronic Module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. ^ Heated backlite/mirror. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8550 Multifunction Electronic Control Module: Testing and Inspection For further information regarding the Generic Electronic Module (GEM), please refer to the system controlled by it: The GEM controls the following features: ^ Wiper Control Module. ^ Audible Warning Device Control Module. ^ Interior Lighting Module. ^ Power Window Control Module. ^ Transfer Case Control Module. ^ Heated Glass Control Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8551 Multifunction Electronic Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION ^ Prior to removal of the module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM) electrical connectors from the (B) GEM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8552 6. Remove the screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams > Page 8557 Seat Memory Switch: Testing and Inspection Remove the memory set switch. Memory Set Switch Measure the resistance between the following indicated terminals while pressing the requested switches. Switch Terminals Memory Switch 1 6 and 4 Memory Switch 2 6 and 3 Memory Set Switch 6 and 1 The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling pinpoint test. Switch Terminals Memory Switch LED 8 and 9 NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8566 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the mat at bottom the of the console bin and remove the screws. ^ To ease removal of the trim panel, pull the front edge back and lift out. 3. Remove the screws and pull out the CD changer and bracket. 4. Disconnect the electrical connectors. 5. Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8567 strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8577 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8578 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8579 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8580 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8581 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8582 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8583 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8589 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8590 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8591 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8592 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8593 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8594 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8595 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8604 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8605 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8606 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8607 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8608 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8609 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8610 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8616 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8617 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8618 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8619 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8620 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8621 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8622 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8623 Speaker: Description and Operation On all vehicles: ^ The rear radio speakers are located behind the rear door trim panels. ^ The front radio speakers are located behind the front door trim panels. ^ The subwoofer is located behind the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8624 Speaker: Service and Repair REMOVAL 1. Remove the door trim panels. 2. Remove the speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair 1. For best performance, it is recommended that the tape player be cleaned once for every 10 to 12 hours of playing time. The tape player should be cleaned using a Ford tape player cleaning cartridge, available at your Ford or Lincoln-Mercury Dealer. The use of other cleaning products is not recommended, as these products could cause damage to the player or cassette tapes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8633 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8634 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8635 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8639 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8642 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8643 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8644 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Locations Multifunction Electronic Control Module: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Locations > Page 8648 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8653 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8654 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8655 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8656 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 Multifunction Electronic Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Multifunction Electronic Control Module: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 Multifunction Electronic Control Module: Electrical Diagrams Diagram 59-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 Diagram 59-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 Diagram 59-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Diagram 59-4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 Diagram 59-5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8672 Multifunction Electronic Control Module: Description and Operation The multi function modules consist of the following: ^ Generic Electronic Module (GEM) The Generic Electronic Module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. ^ Heated backlite/mirror. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8673 Multifunction Electronic Control Module: Testing and Inspection For further information regarding the Generic Electronic Module (GEM), please refer to the system controlled by it: The GEM controls the following features: ^ Wiper Control Module. ^ Audible Warning Device Control Module. ^ Interior Lighting Module. ^ Power Window Control Module. ^ Transfer Case Control Module. ^ Heated Glass Control Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8674 Multifunction Electronic Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION ^ Prior to removal of the module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM) electrical connectors from the (B) GEM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Module <--> [General Module] > Component Information > Diagrams > Page 8675 6. Remove the screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications Remote Anti-Theft Personality Module Nuts 62 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 8679 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 8680 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 8681 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the remote anti-theft personality module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: The antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the NGS Tester into the new module. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 Diagram 95-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 Diagram 95-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8711 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8712 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8713 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8714 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8715 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8716 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8717 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8718 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8721 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8722 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8723 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8724 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8725 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8726 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8727 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8728 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8729 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8730 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8740 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8741 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8742 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8743 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8744 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8745 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8746 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8747 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8748 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8749 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8750 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8751 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8752 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8753 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8754 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8755 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8756 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8757 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8758 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 8759 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery junction box (BJB) Fuse 5 (20 A) ^ BJB Fuse 19 (10 A) ^ BJB Fuse 2O (10 A) ^ BJB Fuse 101 (30 A) ^ BJB Fuse 108 (30 A) ^ Central junction box (CJB) Fuse 23 (10 A) ^ CJB Fuse 13 (10 A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8768 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery junction box (BJB) Fuse 5 (20 A) ^ BJB Fuse 19 (10 A) ^ BJB Fuse 2O (10 A) ^ BJB Fuse 101 (30 A) ^ BJB Fuse 108 (30 A) ^ Central junction box (CJB) Fuse 23 (10 A) ^ CJB Fuse 13 (10 A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8769 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8770 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8771 AB1 - AB2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8772 AC1 - AC2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8773 AC3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8774 AD1 - AD2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8775 AD3 AE Trailer Parking Lamps Inop Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8776 AE1 - AE2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8777 AE3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8778 AE4 - AE5 AF Trailer Lamp Are Inop-Trailer Reversing Lamps Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8779 AF1 - AF2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8780 AF3 - AF4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8781 AF5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8782 AG1 - AG2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8783 AG3 - AG4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8784 AH1 - AH2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8785 AH3 - AH5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 8786 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Trailer Lighting Relay: Testing and Inspection Trailer Tow Running Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 8791 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 8792 Trailer Lighting Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 8793 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8799 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8804 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8805 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8806 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8807 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8809 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8811 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8812 Diagram 95-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8813 Diagram 95-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair Cowl: Service and Repair 1. Remove the windshield wiper pivot arms. 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood. 3. Remove the cowl grille seal. 4. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. NOTE: The two cowl grilles overlap at the center. The LH Cowl grille must be removed first. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair > Page 8821 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Adjust the windshield wiper arms. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Remove the door handle. 1. Disconnect the electrical connector. 2. Remove the nuts. 3. Disconnect the front door latch to lock cylinder rod. 4. Disconnect the front door latch to outside front door handle rod at the handle and at the latch. 5. Remove the door handle by pushing it out from the bottom surface of the handle. NOTE: The front door window glass must be completely raised. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the door handle and lock cylinder rods are not preloading the latch. They should be clipped in a relaxed state with no slack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove and position the inside door handle aside. 1. Remove the screw. 2. Remove and position the inside door handle aside. 3. Disconnect the inside door handle cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair REMOVAL 1. Remove the front inside door handle. NOTE: The front door window glass must be completely up. 2. Remove the watershield. 3. Remove the rear glass channel bolt and position the glass channel aside. 4. Disconnect the rods from the door latch. 1. Disconnect the rods from the door latch. 2. Unclip the locking clip. 3. Disconnect the door lock rod. 5. Position the front door latch aside. 1. Remove and discard the screws. 2. Position the latch aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8835 6. Disconnect the electrical connectors and remove the latch. INSTALLATION 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. NOTE: Install the front door latch screw in the small opening first, followed by the large opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8840 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8841 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel Front Door Panel: Service and Repair Front Door Panel Removal 1. NOTE: Release the top portion first. Remove the sail panel. 2. Remove the window regulator switch plate. 3. Disconnect the electrical connectors. 4. Remove the upper door trim panel screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8844 5. Remove the door trim panel screw at the window regulator switch plate opening. 6. Remove the door trim panel screw in the courtesy lamp housing. 1. Remove the courtesy lamp lens. 2. Remove the screw. 7. Remove the inside door handle trim cover. 8. Remove the inside door handle. - Remove the bolt. 9. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8845 Lift upward and then outward to remove the front door trim panel. 10. Remove the courtesy lamp and socket. 11. Disconnect the power mirror electrical connector. Installation 1. Connect the power mirror electrical connector. 2. Install the courtesy lamp and socket. 3. Install the front door trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8846 4. Install the inside door handle. - Install the bolt. 5. Install the inside door handle trim cover. 6. Install the door trim panel screw in the courtesy lamp housing. 1. Install the screw. 2. Install the courtesy lamp lens. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8847 7. Install the door trim panel screw at the window regulator switch plate opening. 8. Install the upper door trim panel screw. 9. Connect the electrical connectors. 10. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8848 Install the window regulator switchplate. - Insert the rear switchplate clip into the trim panel opening. - Install the forward and side clips into the trim panel opening. 11. NOTE: Install the lower portion first. Install the sail panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8849 Front Door Panel: Service and Repair Front Door Trim Panel Expedition REMOVAL 1. Disconnect the battery ground cable. 2. Remove the sail panel. NOTE: Release the top portion first. 3. Remove the window regulator switch plate. 4. Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8850 5. Remove the top door trim panel screw. 6. Remove the door trim panel screw at the window regulator switch plate opening. 7. Remove the door trim panel screw in the courtesy lamp housing. 1 Remove the courtesy lamp lens. 2 Remove the screw. 8. Remove the inside door handle trim cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8851 9. Remove the inside door handle. - Remove the bolt. 10. Lift upward and then outward to remove the front door trim panel. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. 11. Remove the courtesy lamp. - Turn the courtesy lamp bulb socket one-quarter of a turn and remove. 12. Disconnect the power mirror electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8852 Navigator REMOVAL 1. Disconnect the battery ground cable. 2. On the RH door, remove the sail panel. NOTE: Release the top portion first. 3. Remove the window regulator switch plate. 4. Disconnect the electrical connectors. 5. On the RH door, remove the top door trim panel screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8853 6. Remove the door pull handle screw covers. 7. Remove the door pull handle screws. 8. Remove the inside door handle trim cover. 9. Remove the inside door handle. - Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Panel > Page 8854 10. Lift upward and then outward to remove the front door trim panel. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. 11. Disconnect the electrical connector. 12. On the LH door, disconnect the power mirror electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Lower the window glass to access the two window glass to regulator nuts. 5. Remove the inside glass weatherstrip. 6. Remove the front door rear glass channel bolt and position the channel aside. 7. Remove the window glass to regulator nuts. 8. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 8858 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair For further information regarding this component please refer to Power Window Motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the outside rear door handle. 1. Remove the nuts. 2. Disconnect the rear door latch to outside rear door handle rod. 3. Remove the outside rear door handle by pushing it out from the bottom surface of the handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the door handle and the rear door handle rod is in a relaxed position and that the rear door handle rod is all the way up before closing the clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door latch control remote control. 1. Disconnect the rear door latch rod. 2. Remove the screw. 3. Slide the rear door latch remote control forward and remove. NOTE: The rear window glass must be completely raised. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: The rear door window glass must be completely raised. 1. Remove rear door trim panel. 2. Remove the rear door latch remote control. 1. Disconnect the rear door latch rod. 2. Remove the rear door latch remote control screw. 3. Slide the rear door latch remote control forward and remove. 3. Remove the rear door speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the rear door speaker. 4. Remove the rear door water-shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8873 5. Remove the outside rear door handle. 1. Remove the nuts. 2. Disconnect the rear door latch to outside rear door handle rod. 3. Remove the outside rear door handle by pushing it out from the bottom surface of the handle. 6. Remove the child safety lock finish panel. 7. If equipped, disconnect the power door lock actuator electrical connector. 8. If equipped, drill out the power door lock actuator rivet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8874 9. Drill out the push button rod rivet. 10. Remove the rear door latch. 1. Disconnect the door open warning lamp electrical connector. 2. Remove and discard the screws. 3. Remove the rear door latch through the outside rear door handle opening. - Remove any remaining actuating rods. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8875 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. - Use Heavy Duty Riveter to install the new rivets. NOTE: Make sure the latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Install the rear door latch screw in the small opening first, followed by the large opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8880 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8881 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel Rear Door Panel: Service and Repair Rear Door Panel Removal 1. Remove the window regulator switchplate. 2. Disconnect the electrical connector. 3. Remove the rear door handle trim cover. 4. Remove the rear inside door handle. - Remove the door handle bolt. 5. Remove the rear door trim panel screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel > Page 8884 6. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward. Lift upward and then outward to remove the rear door trim panel. Installation 1. Install the rear door trim panel. 2. Install the rear door trim panel screws. 3. Install the rear inside door handle. - Install the door handle bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel > Page 8885 4. Install the rear door handle trim cover. 5. Connect the electrical connector. 6. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel. 7. Install the window regulator switchplate. - Insert the rear switchplate clip into the trim panel opening. - Install the forward and side clips into the trim panel opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel > Page 8886 Rear Door Panel: Service and Repair Rear Door Trim Panel Expedition REMOVAL 1. Remove the window regulator switch plate. 2. Disconnect the electrical connector. 3. Remove the rear door handle trim cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel > Page 8887 4. Remove the rear inside door handle. - Remove the door handle bolt. 5. Remove the rear door trim panel screws. 6. Lift upward and then outward to remove the rear door trim panel. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward. INSTALLATION 1. To install, reverse the removal procedure. Navigator REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel > Page 8888 1. Remove the door pull handle screws. 1 Remove the screw covers. 2 Remove the screws. 2. Remove the window regulator switch plate. 3. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Panel > Page 8889 4. Remove the rear door handle trim cover. 5. Remove the rear inside door handle. - Remove the door handle bolt. 6. Lift upward and then outward to remove the rear door trim panel. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Remove the inside glass weatherstrip. 5. Remove the rear door glass channel lower bolt. 6. Remove the rear door fixed vent screw. 7. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 8893 8. Remove the window glass to regulator nuts. 9. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Quarter Window Regulator Bracket Bolt 18 in.lb Window Regulator Nuts 7.4-10 ft.lb Front Door Window Regulator Nuts 7.4-10 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the hood latch. 1. Remove the bolts. 2. Disconnect the hood latch cable from the hood latch. 3. Remove the hood latch. INSTALLATION 1. Install the hood latch. 1. Position the hood latch. 2. Connect the hood latch cable to the hood latch. 3. Finger-tighten the bolts. 2. Close the hood. NOTE: The radiator grille may need to be removed to tighten the hood latch bolts. 3. Align the hood flush with the fenders and tighten the hood latch bolts. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Disconnect the rear window defrost grid electrical connector. 2. Remove the liftgate trim panels. 3. Disconnect the liftgate window glass support. 1. Remove the E-clip. 2. Remove the pin. 3. Disconnect the support. NOTE: Have an assistant hold the liftgate window glass. 4. Remove the liftgate window glass. 1. Remove the four bolts (two each side) 2. Remove the liftgate window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 8905 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair Power Trunk / Liftgate Lock Actuator: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Expedition shown, Navigator similar. 1. Remove the liftgate trim panel. 2. Disconnect the power door lock actuator electrical connector. 3. Drill out the rivet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Page 8909 4. Disconnect the power door lock actuator rod and remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate latch remote control bolts and position aside. 3. Remove the liftgate handle. 1. Remove the two nuts. 2. Remove the reinforcement plate. 3. Remove the liftgate handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 8913 NOTE: Make sure the handle shaft and the driver on the liftgate latch controller are properly aligned. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the liftgate trim panel. 3. Separate the liftgate latch from the liftgate. 1. Remove the screws. 2. Separate the liftgate latch from the liftgate. 4. Disconnect the door open warning lamp electrical connector. 5. Disconnect the liftgate latch control cable. - Remove the liftgate latch. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8918 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford Specification ESR-M1C159-A to lubricate the latch. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8919 Trunk / Liftgate Latch: Service and Repair Liftgate Remote Control Latch NOTE: Expedition shown, Navigator similar. REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate latch remote control bolts and position aside. 3. Disconnect the liftgate window glass latch cable. CAUTION: Be careful not to kink the liftgate window glass control cable while disconnecting it. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8920 4. Disconnect the power door lock actuator rod. 5. Disconnect the lock cylinder rod. 6. Disconnect the liftgate latch cable. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8921 7. Remove the liftgate latch remote control. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8922 Trunk / Liftgate Latch: Service and Repair Liftgate Window Glass Latch REMOVAL 1. Remove the liftgate trim panel. 2. Open the liftgate window glass. 3. Disconnect the liftgate window glass control cable. CAUTION: Be careful not to kink the liftgate window glass control cable while disconnecting it. 4 Remove the back window latch. 1. Disconnect the electrical connector. 2. Remove the four screws. 3. Remove the back window latch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8923 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford Specification ESR-M1C159-A to lubricate the latch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8928 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8929 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8930 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8931 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 8932 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 8933 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the liftgate trim panel. 2. Disconnect the lock cylinder rod. 3. Remove the lock cylinder. 1. Remove the retaining clip. 2. Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8943 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8944 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8945 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8946 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8947 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8948 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8949 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8950 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8951 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8952 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8953 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8954 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8955 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8956 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8957 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8958 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8959 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8960 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8961 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8962 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8972 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8973 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8974 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8975 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8976 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8977 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8978 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8979 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8980 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8981 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8982 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8983 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8984 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8985 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8986 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8987 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8988 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8989 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8990 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8991 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Console Finish Panel Front Screw 2.1-2.9 Nm Console Finish Panel Rear Screw 2.1-2.9 Nm Front Floor Console Front Bolts 10.2-13.8 Nm Front Floor Console Rear Bolts 10.2-13.8 Nm Rear Floor Console Front Screws 10.2-13.8 Nm Rear Floor Console Rear Screws 10.2-13.8 Nm Console Rear Panel Screws 1.2-1.8 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Front Floor Console Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Front Floor Console > Page 9002 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Front Floor Console > Page 9003 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console: Service and Repair Front Floor REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console finish panel mat. 3. Remove the console finish panel front screw. 4. Remove the console finish panel rear screw. 5. Remove the console finish panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9006 6. Remove the front floor console front bolts. 7. Disconnect the front floor console electrical connector. ^ If equipped, disconnect the cellular phone electrical connector. 8. Remove the two front floor console rear bolt covers. 9. Remove the two front floor console rear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9007 10. Remove the floor console. ^ Lift the front of the floor console and slide rearward to disengage the floor brackets. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9008 Console: Service and Repair Rear REMOVAL 1. Tilt the rear seats forward. 2. Remove the cofounder. NOTE: Pull upward on the center of the cofounder to release the pin-type retainers. 3. Remove the rear floor console front screws. 4. Remove the two rear floor console rear screws. 5. Remove the rear floor console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor > Page 9009 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9015 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Glove Box Spring Tool SPECIAL SERVICE TOOLS REMOVAL 1. Open the glove compartment. 2. Lower the glove compartment. 1 Move the glove compartment stops to align with the opening. 2 Lower the glove compartment. 3. Install Glove Box Spring Tool Set. 1 Hold the glove compartment open. 2 Install Glove Box Spring Tool Set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 9019 4. Remove the glove compartment. 1 Remove the bolts. 2 Remove the glove compartment. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the safety belt guide nuts. 1 Lift the four covers. 2 Remove the four nuts. 2. Remove the two C-pillar trim panels. NOTE: Remove the upper attachments first, followed by the front lower attachment and the lower rear hook. 3. Remove the A-pillar assist handle. 1 Remove the four covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9023 2 Remove the four screws. 3 Remove the A-pillar assist handle. 4. Remove the two windshield side garnish mouldings. ^ If equipped, on the LH windshield side garnish moulding, disconnect the cellular phone hands-free microphone electrical connector. NOTE: Release the top attachments by pulling inboard first and then upward to release the lower hook. 5. Remove the coat hooks. 1 Remove the two screws. 2 Remove the two coat hooks. 6. Remove the two front door scuff plates. 7. Remove the two rear door scuff plates. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9024 8. Remove the two B-pillar assist handles. 1 Remove the four covers (two on each handle). 2 Remove the four screws two on each handle). 3 Remove the two B-pillar assist handles. 9. Position the two B-pillar trim panels aside. ^ Remove the two front and two rear door weather seals. NOTE: Remove the upper attachments first and then the lower attachments. 10. Remove the two visor arm clips. 1 Remove the two screws. 2 Remove the two visor arm clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9025 11. Remove the two visors. 1 Remove the four screws. 2 Remove the two visors. 12. If equipped, disconnect the visor lamp electrical connector. 13. If equipped, remove the two auxiliary visors. 1 Remove the four screws. 2 Remove the two auxiliary visors. 14. Remove the rear courtesy lamps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9026 15. If equipped, remove the second row seat dome lamp assembly. 1 Remove the lens cover. 2 Remove the screws. 3 Remove the second row seat dome lamp assembly. 16. Remove the rear header garnish trim panel. 17. If equipped, remove the two third row safety belt guides. 1 Lift the two covers. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolts. 3 Remove the two third row safety belt guides. 18. Remove the two D-pillar trim panels. ^ Remove the liftgate door opening weather seal. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9027 19. If equipped, remove the full overhead console (without roof opening panel). 1 Remove the screw from the inside of the sunglass storage bin. 2 Release the three clips and slide the roof console forward and then down. 3 Disconnect the electrical connectors. 20. If equipped, remove the mini overhead console (with roof opening panel). 1 Release the four mounting clips and pull the roof console straight down and forward. 2 Disconnect the electrical connectors. 21. If equipped, remove the rear auxiliary climate control head assembly. 1 Slide the assembly forward and then downward. 2 Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9028 22. If equipped, remove the roof opening panel motor access cover. 1 Pull down to remove the two retaining pin-type retainers at the forward edge. 2 Unhook the cover from the headliner at the rear and remove. 23. If equipped, remove the roof opening panel trim from the headliner. 24. Remove the headliner. 1 Remove the pin-type retainers. 2 Remove the headliner. NOTE: If equipped, remove the auxiliary A/C duct on the LH C-pillar. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel Trim Panel: Service and Repair Liftgate Trim Panel REMOVAL 1. Remove the upper liftgate trim panel. 2. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. 3. Remove the lower lift gate trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9033 Trim Panel: Service and Repair Quarter Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the liftgate door opening weather seal. 2. Remove the liftgate scuff plate. 3. If equipped, remove the third row seat. 4. Remove the rear header garnish trim panel. 5. Remove the rear door scuff plates. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9034 6. Fold down the second row seat. 7. Remove the cross car scuff plate. 8. Remove the second row safety belt guide nut. 1 Lift the cover. 2 Remove the nut. 9. Remove the second row safety belt lower nut. 10. Remove the C-pillar trim panel. ^ Remove the rear door opening weather seal. ^ Remove the C-pillar trim panel. NOTE: Remove the upper attachments followed by the lower attachment and the lower rear hook. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9035 11. If equipped, remove the third row safety belt guide. 1 Lift the cover. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3 Remove the third row safety belt guide. 12. Remove the D-pillar trim panel. ^ Remove the liftgate door opening weather seal. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. 13. Remove the quarter trim panel. 1 Remove the screws and pin-type retainer. 2 Remove the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 9036 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9043 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9044 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9045 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9046 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9047 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 9048 Door Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the front door outside handle. 2. Remove the front door lock cylinder. 1. Remove the retainer. 2. Remove the front door lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9054 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9055 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9056 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the driver door trim panel. 2. Remove the keyless entry keypad. 1. Remove the screw. 2. Remove the speed ruts. 3. Remove the keyless entry keypad. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications Remote Anti-Theft Personality Module Nuts 62 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9060 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9061 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 9062 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the remote anti-theft personality module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: The antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the NGS Tester into the new module. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair PROGRAMMING NOTE: ^ The keyless entry remote transmitters are reprogrammable and must be set at the same time. ^ To program (or reprogram) the keyless entry remote transmitters into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN 8 times within 10 seconds, ending in RUN. If the RAP module has successfully entered the program mode, it will lock and then unlock all doors. 2. Press any button on the keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Diagnosis and Testing. See: Testing and Inspection 4. Turn the ignition switch to the OFF position, or wait up to five minutes after Step 2, to exit the program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair Power Door Lock Actuator: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. NOTE: The rear door window glass must be completely raised. 2. Remove the rear door trim panel. 3. Remove the rear door watershield. 4. Disconnect the power door lock actuator electrical connector. 5. Drill out the power door lock actuator rivet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Page 9070 6. Remove and discard the screws. 7. Remove the power door lock actuator. ^ Disconnect the power door lock actuator rod. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivet. NOTE: ^ Use new screws when installing the rear door latch. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay ALL LOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9075 The All Lock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9076 Power Door Lock Relay: Locations All Unlock Relay ALL UNLOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9077 The All Unlock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9078 Power Door Lock Relay: Locations Driver Unlock Relay DRIVER UNLOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9079 The Driver Unlock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay Power Door Lock Relay: Testing and Inspection All Lock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9082 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9083 Power Door Lock Relay: Testing and Inspection All Unlock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9084 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9085 Power Door Lock Relay: Testing and Inspection Driver's Door Unlock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9086 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Front Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Front Power Door Lock Switch > Page 9091 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9094 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9095 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9096 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9101 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9102 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9103 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9104 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9105 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 9106 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the liftgate trim panel. 2. Disconnect the lock cylinder rod. 3. Remove the lock cylinder. 1. Remove the retaining clip. 2. Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9112 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9113 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9114 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9115 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 Heated Element: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 Diagram 56-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams > Page 9130 Seat Memory Switch: Testing and Inspection Remove the memory set switch. Memory Set Switch Measure the resistance between the following indicated terminals while pressing the requested switches. Switch Terminals Memory Switch 1 6 and 4 Memory Switch 2 6 and 3 Memory Set Switch 6 and 1 The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling pinpoint test. Switch Terminals Memory Switch LED 8 and 9 NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Service and Repair Power Mirror Control Module: Service and Repair DRIVER SEAT MODULE (DSM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9137 Power Mirror Switch: Testing and Inspection Component Testing Procedure (part 1 Of 2) Component Testing Procedure (part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9138 Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9148 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9149 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9150 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9151 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9152 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9158 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9159 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9160 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9161 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 9162 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9163 Paint: By Symptom Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9164 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9165 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9166 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9167 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9168 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9169 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9170 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9171 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9172 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 9173 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications Remote Anti-Theft Personality Module Nuts 62 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9178 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9179 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 9180 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the remote anti-theft personality module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: The antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the NGS Tester into the new module. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay ALL LOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9185 The All Lock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9186 Power Door Lock Relay: Locations All Unlock Relay ALL UNLOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9187 The All Unlock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9188 Power Door Lock Relay: Locations Driver Unlock Relay DRIVER UNLOCK RELAY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 9189 The Driver Unlock Relay is located in the Lock Relay Block. The Lock Relay Block is located behind the Passenger side Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay Power Door Lock Relay: Testing and Inspection All Lock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9192 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9193 Power Door Lock Relay: Testing and Inspection All Unlock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9194 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9195 Power Door Lock Relay: Testing and Inspection Driver's Door Unlock Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > All Lock Relay > Page 9196 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Service and Repair Power Mirror Control Module: Service and Repair DRIVER SEAT MODULE (DSM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module Power Seat Control Module: Diagrams Driver's Seat Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 9204 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 9205 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 9206 Power Seat Control Module: Diagrams Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 9207 Power Seat Control Module: Description and Operation The power driver seat and power outside rear view mirrors are controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM system consists of the following components. ^ Driver seat module. ^ Driver memory seat switch. ^ Memory mirror switch. ^ Memory set switch. ^ Front vertical seat motor. ^ Rear vertical seat motor. ^ Driver horizontal memory mirror. ^ LH heated memory mirror. ^ RH heated memory mirror. ^ Remote entry key fob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Power Seat Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 9210 Power Seat Control Module: Service and Repair Heated Seat Module REMOVAL 1. Remove the power seat track. 2. Disconnect the electrical connectors. 3. Remove the heated seat module. ^ Release the clip. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 9211 Power Seat Control Module: Service and Repair Seat Module REMOVAL 1. Remove the power seat track. 2. Remove the seat module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the roof opening panel. 2. Disconnect the battery ground cable. 3. Remove the access cover. 4. Slide the roof opening panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair Sunroof / Moonroof Cable: Service and Repair DRIVE CABLES AND GUIDE RAILS DISASSEMBLY 1. Remove the roof opening panel frame. 2. Remove the water trough. 1. Remove the bolts. 2. Remove the water trough. 3. Remove the water trough guide by sliding it back and lifting it outward at the notch in the tracks. ASSEMBLY 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Service and Repair Sunroof / Moonroof Cable Housing: Service and Repair DRIVE CABLES AND GUIDE RAILS DISASSEMBLY 1. Remove the roof opening panel frame. 2. Remove the water trough. 1. Remove the bolts. 2. Remove the water trough. 3. Remove the water trough guide by sliding it back and lifting it outward at the notch in the tracks. ASSEMBLY 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 9229 Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Remove the access cover. NOTE: The roof opening panel should be in the closed position. 2. Remove the three bolts. 3. Disconnect the electrical connector and remove the roof opening panel motor. INSTALLATION NOTE: The roof opening panel module must be installed prior to motor installation. 1. Connect the electrical connector. NOTE: The roof opening panel should be in the closed position. 2. Cycle the roof opening panel motor until it stops in the closed position. 3. Remove the roof opening panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 9230 4. Insert two 1/8 inch pins through both portions of the lifter assemblies. 5. Install the roof opening panel motor. ^ Install the three bolts. NOTE: It may be necessary to rotate the roof opening panel motor slightly to engage the drive splines. 6. Remove the pins. 7. Install the roof opening panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the roof opening panel. 2. Disconnect the battery ground cable. 3. Remove the access cover. 4. Slide the roof opening panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams > Page 9245 Seat Memory Switch: Testing and Inspection Remove the memory set switch. Memory Set Switch Measure the resistance between the following indicated terminals while pressing the requested switches. Switch Terminals Memory Switch 1 6 and 4 Memory Switch 2 6 and 3 Memory Set Switch 6 and 1 The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling pinpoint test. Switch Terminals Memory Switch LED 8 and 9 NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module Power Seat Control Module: Diagrams Driver's Seat Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 9250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 9251 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Driver's Seat Module > Page 9252 Power Seat Control Module: Diagrams Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Page 9253 Power Seat Control Module: Description and Operation The power driver seat and power outside rear view mirrors are controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM system consists of the following components. ^ Driver seat module. ^ Driver memory seat switch. ^ Memory mirror switch. ^ Memory set switch. ^ Front vertical seat motor. ^ Rear vertical seat motor. ^ Driver horizontal memory mirror. ^ LH heated memory mirror. ^ RH heated memory mirror. ^ Remote entry key fob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Power Seat Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 9256 Power Seat Control Module: Service and Repair Heated Seat Module REMOVAL 1. Remove the power seat track. 2. Disconnect the electrical connectors. 3. Remove the heated seat module. ^ Release the clip. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 9257 Power Seat Control Module: Service and Repair Seat Module REMOVAL 1. Remove the power seat track. 2. Remove the seat module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's Seat Motor Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's Seat Motor Assembly > Page 9262 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Seat Regulator Control Switch Screws 9-26 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch Power Seat Switch: Diagrams Driver's Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 9268 Power Seat Switch: Diagrams Heated Seat Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 9269 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch Power Seat Switch: Testing and Inspection Driver's Seat Control Switch With Memory Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9272 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9273 Without Memory Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9274 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9275 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9276 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9277 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9278 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9279 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 9280 Power Seat Switch: Service and Repair NOTE: Driver side shown, passenger side similar. REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1. Remove the screw. 2. Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 9281 5. Remove the pin-type retainer on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1. Remove the screws. 2. Disconnect the seat regulator control switch. NOTE: If equipped with heated seats, disconnect the switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 9282 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ If equipped with heated seats, connect the switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track Seat Track: Service and Repair Manual Seat Track REMOVAL 1. Remove the front seat back adjust handle. 1. Remove the screw. 2. remove the front seat back adjust handle. 2. Pull to remove the front seat lumbar support handle. 3. Remove the front seat track shield screws. 4. Remove the pin-type retainer on the back of the front seat track shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track > Page 9287 5. Remove the screws on the bottom of the front seat track shield. 6. Remove the seat track to seat cushion front bolts. 1. Position the seat track rearward. 2. Remove the seat track to seat cushion front bolts. 7. Remove the seat track assembly. 1. Position the seat track forward. 2. Remove the seat track rear bolts. 3. Remove the seat track assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track > Page 9288 1. Install the seat track. 1. Position the seat track. 2. Loosely install the seat track rear bolts. 2. Install the seat track to seat cushion front bolts. 1. Position the seat track rearward. 2. Install the seat track to seat cushion front bolts. 3. Tighten the seat track rear bolts. 4. Install the screws on the bottom of the front seat track shield. 5. Install the pin-type retainer on the back of the front seat track shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track > Page 9289 6. Install the front seat track shield screws. 7. If equipped, install the lumbar support handle. 8. Install the seat back adjust handle. ^ Install the screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track > Page 9290 Seat Track: Service and Repair Power Seat Track REMOVAL 1. Remove the four seat track to seat cushion bolts. 2. Disconnect the electrical connectors. 3. Remove the seat track. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Power Door Lock Switch > Page 9296 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9299 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9300 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9301 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9305 Power Mirror Switch: Testing and Inspection Component Testing Procedure (part 1 Of 2) Component Testing Procedure (part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9306 Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Seat Regulator Control Switch Screws 9-26 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch Power Seat Switch: Diagrams Driver's Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 9312 Power Seat Switch: Diagrams Heated Seat Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver's Seat Control Switch > Page 9313 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch Power Seat Switch: Testing and Inspection Driver's Seat Control Switch With Memory Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9316 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9317 Without Memory Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9318 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9319 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9320 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9321 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9322 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver's Seat Control Switch > Page 9323 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 9324 Power Seat Switch: Service and Repair NOTE: Driver side shown, passenger side similar. REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1. Remove the screw. 2. Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 9325 5. Remove the pin-type retainer on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1. Remove the screws. 2. Disconnect the seat regulator control switch. NOTE: If equipped with heated seats, disconnect the switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 9326 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ If equipped with heated seats, connect the switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Page 9330 Seat Memory Switch: Testing and Inspection Remove the memory set switch. Memory Set Switch Measure the resistance between the following indicated terminals while pressing the requested switches. Switch Terminals Memory Switch 1 6 and 4 Memory Switch 2 6 and 3 Memory Set Switch 6 and 1 The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling pinpoint test. Switch Terminals Memory Switch LED 8 and 9 NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: Customer Interest Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 9342 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: All Technical Service Bulletins Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 9348 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair Cowl: Service and Repair 1. Remove the windshield wiper pivot arms. 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood. 3. Remove the cowl grille seal. 4. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. NOTE: The two cowl grilles overlap at the center. The LH Cowl grille must be removed first. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair > Page 9353 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Adjust the windshield wiper arms. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9362 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9363 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9364 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9370 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9371 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 9372 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9383 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9385 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9386 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9387 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9388 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9389 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9390 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9391 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9392 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9393 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9394 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9395 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9396 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9399 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9401 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9402 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9404 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9405 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9406 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9407 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Deactivator Switch: Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9412 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Deactivator Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9422 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9423 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9424 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9425 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9426 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9427 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9428 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9438 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9439 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9440 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9441 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9442 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9443 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9444 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9445 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9446 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9447 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9448 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9449 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9450 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9451 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9452 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9453 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9454 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9456 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9457 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9458 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9459 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9460 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9461 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9462 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Deactivator Switch: Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9468 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Deactivator Switch: > 01-7-3 > Apr > 01 > Recalls for Deactivator Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Deactivator Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9478 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9479 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9480 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9481 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9482 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9483 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9484 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9485 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9486 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9487 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9488 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9489 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9490 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9491 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9492 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9493 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9496 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9497 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9498 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9499 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9500 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9502 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9503 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9512 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9513 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9514 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9515 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9516 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9517 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9518 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9529 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9530 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9531 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9532 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9533 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9534 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9535 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9541 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9542 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9543 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9544 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9545 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9546 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo Noise Filter: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9547 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Special Tools Removal 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Remove the pinion seal. Installation 1. Clean the pinion seal bore, and use the Pinion Seal Replacer to install the pinion seal. 2. Install the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > System Information > Service and Repair > Front Drive Axle > Page 9551 Seals and Gaskets: Service and Repair 8.8 Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and remove. Installation 1. Lubricate the new rear axle drive pinion seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace with a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > System Information > Service and Repair > Front Drive Axle > Page 9552 Seals and Gaskets: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the new rear axle drive pinion seal. ^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive 3. Install the pinion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > System Information > Tools and Equipment > Front Drive Axle Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > System Information > Tools and Equipment > Front Drive Axle > Page 9555 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > System Information > Tools and Equipment > Front Drive Axle > Page 9556 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Component Information > Specifications Speed Sensor: Specifications Output speed sensor bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Component Information > Specifications > Page 9562 Temperature Sensor (Gauge): Service and Repair Removal 1. Partially drain the engine cooling system. 2. On 4.6L engines, disconnect the connector and remove the water temperature indicator sender unit. 3. On 5.4L engines, disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. ^ Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket Bolts ........................................................................................................................................... 7.6-10.4 N.m (5.6-7.7 Lb-Ft) Speed Control Servo Bracket Screws ............................................................................................................................................ 10-13 N.m (90-115 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9566 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9567 Cruise Control Servo: Service and Repair REMOVAL 1. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. 2. Disconnect the speed control actuator cable from the speed control servo. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. 3. Disconnect the speed control servo electrical connector. 4. Remove the speed control servo and bracket. 1 Remove the bolts. 2 Remove the speed control servo and bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9568 NOTE: Do not remove the rubber grommets from the speed control servo bracket. 5. Remove the speed control servo bracket. 1 Remove the screws. 2 Remove the speed control servo bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rubber grommets must be properly seated in the speed control servo bracket for proper noise and vibration isolation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair REMOVAL NOTE: 5.4L 2 Valve Triton V8 shown; others are similar. 1. Remove the accelerator control splash shield. 1 Remove the screws. 2 Remove the accelerator control splash shield. 2. Remove the speed control actuator cable from the throttle nail head. 1 Lift the speed control actuator cable upward. 2 Squeeze the speed control actuator cable tabs and remove from the throttle nail head. 3. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9572 4. Remove the speed control actuator cable. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and remove the speed control actuator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9586 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9587 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9597 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9598 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9599 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9600 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9601 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9602 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9603 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9604 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9605 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9606 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9607 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9608 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9609 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9610 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9611 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9612 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9613 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9614 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9615 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9616 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9617 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9618 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9619 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9620 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9621 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9622 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Deactivator Switch: Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9627 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Deactivator Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Deactivator Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9637 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9638 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9639 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9640 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9641 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9642 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9643 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9644 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9645 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9646 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9647 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9648 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9649 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9650 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9651 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9652 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9653 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9656 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9657 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Deactivator Switch: All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9667 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Deactivator Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Deactivator Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Page 9672 Deactivator Switch: Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-15 Lb-In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch Deactivator Switch: Service and Repair Brake Pedal Position (BPP) Switch REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 3. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the (A) BPP switch from the (B) brake master cylinder push rod. 3 Remove the brake master cylinder push rod spacer. 4 Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Deactivator Switch <--> [Brake Switch (Cruise Control)] > Component Information > Service and Repair > Brake Pedal Position (BPP) Switch > Page 9675 Deactivator Switch: Service and Repair Deactivator Switch REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running, water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9689 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9690 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9700 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9706 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9711 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9712 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9713 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9714 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9715 Audible Warning Device: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9716 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9717 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9718 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9721 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9722 Audible Warning Device: Electrical Diagrams Diagram 66-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9723 Diagram 66-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 9724 Audible Warning Device: Description and Operation The warning device system consists of the following: ^ safety belt warning lamp switch ^ door ajar switch ^ Generic Electronic Module (GEM) ^ key-in-ignition warning switch ^ headlamp on warning ^ low washer fluid warning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Audible Warning Device: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Key-in-ignition/key position warning switch ^ Door open warning lamp switch ^ Safety belt warning indicator switch ^ Headlamp ^ Low washer fluid ^ 4x4 indicator lamp Electrical ^ Fuse(s) ^ Damaged wiring harness ^ Loose or corroded connections ^ Circuitry 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If NGS does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If NGS Tester responds with: ^ CKT914, CKT915 or CKT70= ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test G. See: Pinpoint Tests/G: No Communication With Generic Electronic Module (GEM) ^ SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved,proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9727 Audible Warning Device: Diagnostic Trouble Code Descriptions Part 1 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9728 Part 2 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9729 Part 3 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9730 Part 4 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9731 Part 5 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9732 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9733 Audible Warning Device: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A: Safety Belt Warning Chime Doesn't Operate Correctly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9734 A1 - A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9735 A3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9736 A4 - A6 B: The Key-In-Ignition Chime Is Inop (LF Door Only) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9737 B1 - B3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9738 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9739 B6 C1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9740 D1 - D3 E: Headlamp On Reminder Chime Not Operating Properly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9741 E1 - E3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9742 E4 - E6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9743 E7 - E8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9744 E9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9745 F1 - F3 G: No Communication With Generic Electronic Module (GEM) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9746 G1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9747 G2 - G3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9748 G4 - G5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9749 Audible Warning Device: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Key-in-ignition/key position warning switch ^ Door open warning lamp switch ^ Safety belt warning indicator switch ^ Headlamp ^ Low washer fluid ^ 4x4 indicator lamp Electrical ^ Fuse(s) ^ Damaged wiring harness ^ Loose or corroded connections ^ Circuitry 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If NGS does not communicate with the vehicle: ^ Check that the program card is properly installed. ^ Check the connections to the vehicle. ^ Check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If NGS Tester responds with: ^ CKT914, CKT915 or CKT70= ALL ECUS NO RESP/NOT EQUIP, refer to Information Bus. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test G. See: Pinpoint Tests/G: No Communication With Generic Electronic Module (GEM) ^ SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved,proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Diagnostic Trouble Code Descriptions Part 1 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9750 Part 2 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9751 Part 3 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9752 Part 4 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9753 Part 5 0f 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9754 Icons Used With Pinpoint Tests Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9755 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A: Safety Belt Warning Chime Doesn't Operate Correctly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9756 A1 - A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9757 A3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9758 A4 - A6 B: The Key-In-Ignition Chime Is Inop (LF Door Only) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9759 B1 - B3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9760 B4 - B5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9761 B6 C1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9762 D1 - D3 E: Headlamp On Reminder Chime Not Operating Properly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9763 E1 - E3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9764 E4 - E6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9765 E7 - E8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9766 E9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9767 F1 - F3 G: No Communication With Generic Electronic Module (GEM) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9768 G1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9769 G2 - G3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9770 G4 - G5 Principles of Operation The Generic Electronic Module (GEM) controls the following warnings and chimes: ^ Driver safety belt not fastened warning (warning lamp and repetitive chime). ^ Key-in-ignition warning (repetitive chime). ^ Headlamp-on warning (repetitive chime). ^ Door ajar warning (warning lamp and single tone). ^ Low washer fluid warning (warning lamp and single tone). The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning chime will sound when the driver safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning chime will stop sounding when the safety belt is fastened, when the ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position, and when the chime has sounded for six seconds. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9771 The safety belt warning chime inputs are: ^ Ignition switch START position (battery potential when in START position). ^ Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs). ^ Driver safety belt switch (grounded when not fastened; open circuit when fastened). The safety belt warning lamp warns that the safety belt is not fastened. The safety belt warning lamp illuminates when it is grounded and turns off when the circuit is open. The safety belt warning lamp will be illuminated when the safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning lamp will turn off when the safety belt is fastened, the ignition switch is moved from the RUN or START to the OFF/LOCK or ACC position, or if the lamp is illuminated for 61 seconds. The safety belt warning lamp inputs are: ^ Ignition switch START position (battery potential when in START). ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Driver safety belt switch (grounded when not fastened; open circuit when fastened). The door ajar warning tone warns that a door is ajar. The door ajar warning tone is a single tone with a duration of one second. The tone will sound when the right from:, right rear1, left front, left rear, liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN position. The door ajar warning tone inputs are: ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Door open warning lamp switches (grounded when ajar; open circuit when closed). The door ajar warning lamp warns that a door is ajar. The door ajar warning lamp illuminates when it is grounded. The door ajar warning lamp will be illuminated when any door, the liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN or START position. The door ajar warning lamp will turn off when all doors, the liftgate glass and the liftgate are closed, or the ignition switch is turned to the OFF/LOCK or ACC position. The door ajar warning lamp inputs are: ^ Ignition switch START position (battery potential when in START). ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Door open warning lamp switches (grounded with door ajar; open circuit with door closed). The key-in-ignition warning chime warns that the key is still in the ignition when the driver door is ajar. The key-in-ignition warning chime will sound when the driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position and the key is in the ignition. The key-in-ignition warning chime will stop sounding when the driver door is closed, the key is removed from the ignition, or if the ignition switch is moved to the RUN position. The key-in-ignition warning chime inputs are: ^ Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). ^ Ignition switch ACC position (battery potential on RUN/ACC input only). ^ Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). ^ LF door open warning lamp switch (open circuit with door closed; grounded with door ajar). The headlamp on warning chime warns that the headlamps are on when the driver door is ajar and key is out. The headlamps on warning chime will sound if the driver door is ajar, the headlamp switch is in the PARK or HEAD position, and the ignition switch state is in the OFF/LOCK position with the key out. The headlamp on warning chime will stop sounding when any one of the conditions above are removed. The headlamp on warning chime inputs are: ^ Ignition switch OFF/LOCK (open circuit on all ignition inputs). ^ Headlamp switch (battery potential when in PARK or HEAD position; open circuit when in OFF position). ^ LF door open warning lamp switch (open circuit with door closed; grounded with door ajar). ^ Key-in-ignition switch (grounded with key-in-ignition; open circuit with key-out). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9772 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9773 GEM Parameter Identification Index Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9774 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9775 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Description and Operation Audible Warning Device Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Description and Operation > Page 9779 Audible Warning Device Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Testing and Inspection Charge Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9790 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9791 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9792 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9793 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9794 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9795 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9796 Cigarette Lighter: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9797 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9798 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9799 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9801 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9802 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9803 Diagram 44-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Specifications Clock: Specifications Clock Screws 1.0-2.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions Clock: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9809 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9810 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9811 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9812 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9813 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9814 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9815 Clock: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9816 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9817 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9818 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9823 Diagram 44-4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 9824 Clock: Description and Operation The electric clock, centrally located on the instrument panel, displays time in a 12 hour format. The display illuminates with the ignition switch is in ACC or RUN and dims when the headlights are on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Clock: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the electric clock. 2. Visually inspect for obvious signs of mechanical and/or electrical damage: VISUAL INSPECTION CHART Mechanical ^ Damaged electric clock Electrical ^ Blown fuse: I/P Fuse 2 (5 A) - I/P Fuse 8 (5 A) - I/P Fuse 18 (5 A) ^ Damaged wire(s) ^ Loose or corroded connectors 3. If an obvious cause for an observed or reported malfunction is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9827 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9828 Clock: Pinpoint Tests Icons Used With Pinpoint Test Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Test A : Clock Operation Erratic or Inoperative Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9829 A1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9830 A2 - A3 A4 - A5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9831 A6 - A7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9832 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 9833 Clock: Service and Repair REMOVAL 1. Release the clip and remove the electric clock and housing from the instrument panel. NOTE: The electric clock is held in place by spring clips located on the back of the housing. 2. Disconnect the electric clock electrical connector. 3. Remove the two screws and remove the electric clock from the housing. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9843 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Testing and Inspection Door/Trunk Ajar Indicator/Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Driver Information/Message Center Driver/Vehicle Information Display: Description and Operation Driver Information/Message Center The message center is located in the overhead console and consists of the following components: ^ Powertrain Control Module (PCM) ^ compass sensor module ^ message center ^ fuel level sensor and pump ^ Output Shaft Speed (OSS) sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Driver Information/Message Center > Page 9851 Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It Work?) Average (AVG) Fuel Economy - Resetting NOTE: Only the AVG fuel economy can be reset. DTE and INST displays cannot be reset. The AVG fuel economy display is resettable. To reset, the ignition switch must be in the RUN position (with or without the engine running) and the message center must be in the AVG fuel economy display mode. Press and release the MODE and E/M buttons simultaneously. If the vehicle is parked while resetting, the AVG fuel economy will display 0.0 (English mode) or 99.9 (metric mode). If the vehicle is in motion, the AVG fuel economy will display the current INST fuel economy (English mode or metric mode). Information and Message Center NOTE ^ The Distance To Empty (DTE) display may be inaccurate if the vehicle is started while parked on an incline. ^ Fuel fills of less than 22.7 liters (6 gallons) may not be detected by the message center. ^ The Instantaneous (INST) fuel economy feature is only available on early production vehicles. The message center uses inputs from the fuel level sensor and pump, the compass sensor module and the Powertrain Control Module (PCM). The input from the PCM is the vehicle speed signal. The PCM gets the vehicle speed signal from the Output Shaft Speed (OSS) sensor. From those inputs, the message center displays: ^ compass direction. ^ DTE. ^ average (AVG) fuel economy. ^ INST fuel economy (if equipped). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged overhead trip computer ^ Damaged OSS sensor ^ Damaged compass sensor module or loose mounting ^ PCM Electrical ^ Blown central junction box (CJB) fuse 6: Fuse 2 (5 A) - Fuse 6 (5 A) ^ Damaged wiring harness ^ Loose or corroded connections 3. If the fault is not visually evident, perform the Message Center Self-Test. See: Component Tests and General Diagnostics Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9855 Driver/Vehicle Information Display: Pinpoint Tests A: The Compass Is Inaccurate A1 - A3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9856 A4 - A5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9857 A6 - A7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9858 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9859 C1 D: Dist. To Empty/Av/Instant Fuel Economy Inop/Incorrect Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9860 D1 - D2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9861 D3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9862 D4 - D5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9863 E1 F1 Icons Used With Pinpoint Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9864 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9865 Driver/Vehicle Information Display: Component Tests and General Diagnostics Message Center Message Center Self-Test (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9866 Message Center Self-Test (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9867 Message Center Self-Test (Part 3 Of 3) 1. The Message Center Self-Test can be entered by pressing the E/M and MODE buttons simultaneously while starting the vehicle. After entering the Message Center Self-Test release the E/M and MODE buttons. Advancing to a desired test is accomplished by pressing the MODE button. To abort the Message Center Self-Test, turn the ignition switch to the OFF position. NOTE: Vehicle doors must be closed and the engine must be running while in the Message Center Self-Test mode to receive accurate data. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Zone Adjustment Driver/Vehicle Information Display: Adjustments Compass Zone Adjustment 1. The zone setting is factory pre-set to Zone 8. Check the Compass Calibration Zone map to verify the correct compass zone setting for your geographic location. 2. Insert an appropriate-diameter rod, preferably non-metallic, into the switch access hole underneath the compass module. Gently press the switch for one to two seconds until ZONE and the current zone setting are displayed. 3. Release the switch. 4. Press the switch repeatedly to cycle the display through all possible zone settings. Stop cycling when the correct zone setting for your location is displayed. 5. Release the switch to exit the zone setting mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Zone Adjustment > Page 9870 Driver/Vehicle Information Display: Adjustments Calibration Adjustment 1. For optimum calibration, turn off all non-essential electrical accessories (rear window defrost, heater/air conditioning, map lamps, wipers, etc.) and make sure all doors are shut. 2. Drive to an open, level area away from large metallic objects or structures and high voltage lines. 3. Insert an appropriate-diameter rod, preferably non- metallic, into the switch access hole underneath the compass module. Press gently for two to four seconds until CAL and a direction are displayed. 4. Release the switch and drive slowly in a circle until CAL disappears from the display (about two to three circles). 5. The compass is now calibrated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Removal and Installation Driver/Vehicle Information Display: Service and Repair Removal and Installation MESSAGE CENTER ASSEMBLY REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console and pull down to remove the console. 3. Disconnect the electrical connectors. 4. Remove the message center. 1 Depress the lock tab underneath the in-line electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Removal and Installation > Page 9873 2 Remove the in-line connector. 3 Remove the screws. 4 Remove the message center. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Removal and Installation > Page 9874 Driver/Vehicle Information Display: Service and Repair Vehicle Demagnetizing 1. CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a clothe over the vehicle's roof to protect the vehicle's surface if contact occurs. Make sure the clothe covers the front third and the entire width of the roof. NOTE ^ The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. ^ To demagnetize, use a constant circular motion over the vehicle's roof. Do not turn off the demagnetizer while sweeping the vehicle's roof to prevent remagnetizing ferrous materials contained in the vehicle. ^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle's surface. 2. Demagnetize the front third of the vehicle's roof. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 3. Demagnetize the inside rear view mirror mounting pad. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 3 Turn the demagnetizer off. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm(1 in). 4. Perform the Compass Zone Adjustment procedure. See: Adjustments/Compass Zone Adjustment 5. Perform the Calibration Adjustment procedure. See: Adjustments/Calibration Adjustment Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9875 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 9884 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 9890 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Page 9891 Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection Fuel Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. REACTIVATION PROCEDURE 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9900 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the three-way connector at the base of the steering column connected? ............................................................................................................... [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? .............................................................................................................................................. [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL 1. Remove the instrument cluster. 2. Remove the necessary instrument cluster bulb(s). ^ Remove the back cover if necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9912 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9913 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9914 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9920 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9921 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9922 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Fry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair > Page 9926 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 9933 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection Odometer: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED indicator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch 9-11 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 9949 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation Audible Warning Device Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 9954 Audible Warning Device Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9963 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9964 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9965 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9971 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9972 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9973 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 9982 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 9988 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Page 9989 Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Fry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair > Page 10000 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Specifications Shift Indicator: Specifications Transmission Column Shift Selector Tube Bracket Bolts ........................................................................................................................ 14 Nm (10 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Specifications > Page 10004 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. ^ Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. ^ Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. ^ Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10013 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10019 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10025 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10026 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10032 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10033 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Page 10034 Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water Temperature Sensor 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 10044 Temperature Sensor (Gauge): Service and Repair Removal 1. Partially drain the engine cooling system. 2. On 4.6L engines, disconnect the connector and remove the water temperature indicator sender unit. 3. On 5.4L engines, disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. ^ Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection Transmission Shift Position Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10067 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10073 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10076 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10077 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10078 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10079 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10080 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10081 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10082 Brake Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10083 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10084 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10085 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10086 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10087 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10088 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10089 Brake Lamp: Electrical Diagrams Diagram 90-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10090 Diagram 90-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10091 Diagram 90-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10092 Diagram 90-4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10093 Diagram 90-5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Brake Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged brake pedal position switch Electrical ^ Central junction box Fuse 13 (15 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10096 Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged brake pedal position switch Electrical ^ Central junction box Fuse 13 (15 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10097 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10098 Brake Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10099 K1 - K2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10100 L1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10101 L2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10102 M1 - M3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10103 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch 1. Remove the self-locking pin. 2. Remove the spacer 3. Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10115 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 10121 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10122 Center Mounted Brake Lamp: Service and Repair REMOVAL 1. Remove the window glass moulding. 2. Remove the high mounted stoplamp assembly. 1. Remove the screws. 2. Remove the high mounted stoplamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Testing and Inspection Courtesy Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Testing and Inspection > Page 10127 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Glove Box Lamp: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10132 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate the interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 10140 The Daytime Running Lamp Relay 1 and 2 are located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 Daytime Running Lamp Relay: Testing and Inspection DRL Relay #1 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 10143 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 10144 Daytime Running Lamp Relay: Testing and Inspection DRL Relay #2 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 10145 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Saver Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10150 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10151 Battery Saver Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10152 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10153 Battery Saver Relay: Description and Operation The following components are controlled by the battery saver relay: - front map lamp assembly - Front door courtesy lamp - Generic electronic module (GEM) - Glove box lamp assembly - Central security module - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay - Illuminated vanity mirrors (Navigator only) The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, or in the sleep mode, (relay coil is de-energized). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10154 Battery Saver Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10155 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The fog lamp bulb should not be removed from the fog lamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the fog lamp bulb electrical connector. 3. Rotate the fog lamp socket counterclockwise and remove. INSTALLATION 1. To install, reverse the removal procedure. NOTICE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10163 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10164 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10165 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10170 Hazard Warning Flasher: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10171 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10175 Hazard Warning Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10176 Hazard Warning Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10177 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. REMOVAL 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb by pulling it straight out with a gentle tip-and-down rocking motion. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Be sure the headlamp assembly is positioned correctly with the alignment pins inserted into the proper holes and onto the ribs of the reinforcement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations NOTE: The Autolamp Module and the Headlamp Control Module are the same component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Locations > Page 10185 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10189 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10190 Headlamp Dimmer Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10191 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10192 Headlamp Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10193 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 10197 Headlamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 10198 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Main Light Switch Headlamp Switch: Diagrams Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Main Light Switch > Page 10203 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Main Light Switch > Page 10204 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10205 Headlamp Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10206 Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10207 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10208 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10209 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1. Pull the headlamp switch from the instrument panel. 2. Disconnect the electrical connectors INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Testing and Inspection Hi-Beam Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10217 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10218 Horn Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10219 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL AND INSTALLATION NOTE: The steering wheel pad horn switch is part of the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation Interior Lighting Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation > Page 10226 Interior Lighting Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10230 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10235 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10236 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10237 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10238 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10239 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10240 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10241 License Plate Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10242 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10243 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10244 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10245 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10246 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10247 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10248 License Plate Lamp: Electrical Diagrams Diagram 92-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10249 Diagram 92-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10250 Diagram 92-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis License Plate Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery junction box Fuse 7 (15 A) ^ Central junction box Fuse 4 (5 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10253 License Plate Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery junction box Fuse 7 (15 A) ^ Central junction box Fuse 4 (5 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10254 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10255 License Plate Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10256 R1 - R2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10257 S1 - S2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10258 S3 - S4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10259 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10260 U1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10261 U2 - U3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10262 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Remove the map lamp assembly. 2. Release the clip on the bulb(s) to be replaced. 3. Remove the map lamp bulb. 1. Remove the map lamp reflector. 2. Remove the map lamp bulb from the clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10277 Marker Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10278 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10279 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10280 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10281 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10282 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10283 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10284 Marker Lamp: Electrical Diagrams Diagram 92-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10285 Diagram 92-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10286 Diagram 92-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10291 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10292 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Saver Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10298 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10299 Battery Saver Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10301 Battery Saver Relay: Description and Operation The following components are controlled by the battery saver relay: - front map lamp assembly - Front door courtesy lamp - Generic electronic module (GEM) - Glove box lamp assembly - Central security module - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay - Illuminated vanity mirrors (Navigator only) The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, or in the sleep mode, (relay coil is de-energized). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10302 Battery Saver Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Saver Relay <--> [Battery Discharge Protection Relay, Lighting] > Component Information > Technical Service Bulletins > Page 10303 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Testing and Inspection Courtesy Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Testing and Inspection > Page 10307 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 10311 The Daytime Running Lamp Relay 1 and 2 are located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 Daytime Running Lamp Relay: Testing and Inspection DRL Relay #1 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 10314 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 10315 Daytime Running Lamp Relay: Testing and Inspection DRL Relay #2 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > DRL Relay #1 > Page 10316 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10320 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10321 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10322 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations NOTE: The Autolamp Module and the Headlamp Control Module are the same component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations > Page 10326 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 10330 Headlamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 10331 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10335 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10336 Horn Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10337 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation Interior Lighting Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation > Page 10341 Interior Lighting Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10345 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10349 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10350 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Trailer Lighting Relay: Testing and Inspection Trailer Tow Running Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 10355 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 10356 Trailer Lighting Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 10357 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch 1. Remove the self-locking pin. 2. Remove the spacer 3. Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10373 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10374 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10375 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10376 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10377 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10378 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10379 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10380 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10381 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10383 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Fry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Page 10387 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10399 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10400 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10401 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10402 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10403 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10404 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10405 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10406 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10407 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 01-14-1 > Jul > 01 > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10408 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10412 Hazard Warning Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10413 Hazard Warning Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10414 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10418 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10419 Headlamp Dimmer Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10420 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10421 Headlamp Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10422 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Main Light Switch Headlamp Switch: Diagrams Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Main Light Switch > Page 10427 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Main Light Switch > Page 10428 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10429 Headlamp Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10430 Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10432 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10433 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1. Pull the headlamp switch from the instrument panel. 2. Disconnect the electrical connectors INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL AND INSTALLATION NOTE: The steering wheel pad horn switch is part of the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1. Disconnect the electrical connector. 2. Rotate the interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10443 Turn Signal Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10446 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10447 Turn Signal Switch: Diagnostic Trouble Code Descriptions GEM Diagnostic Trouble Code Index Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10448 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10449 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10450 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10451 Part 5 Of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10452 Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10453 Turn Signal Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10454 Turn Signal Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10455 diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures GEM Diagnostic Trouble Code Index Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10456 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10457 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10458 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10459 Part 5 Of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10460 Part 1 Of 2 Part 2 Of 2 Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10461 Test A: No Communication With The Module-GEM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10462 Test A1 - A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10463 Test A3 - A4 Test A5 Test B: Unable To Enter Self-Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10464 Test B1 Test C: The Ignition Switch Is Inoperative Test C1 Test D: No Power In ACC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10465 Test D1 Test E: No Power In RUN Test E1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10466 Test E1 - E2 Test F: No Power In START Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10467 Test F1 - F2 Component Tests and General Diagnostics Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10468 Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10469 Pinout Values and Diagnostic Parameters Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10470 Part 1 Of 3 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10471 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10472 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10473 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10474 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear Lamp Screws 24.7-37.1 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10480 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10481 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10482 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10483 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10484 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10485 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 Tail Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 Tail Lamp: Electrical Diagrams Diagram 92-1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 Diagram 92-2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 Diagram 92-3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Tail Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery junction box Fuse 7 (15 A) ^ Central junction box Fuse 4 (5 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10498 Tail Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery junction box Fuse 7 (15 A) ^ Central junction box Fuse 4 (5 A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10499 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10500 Tail Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10501 R1 - R2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10502 S1 - S2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10503 S3 - S4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10504 T1 - T2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10505 U1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10506 U2 - U3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10507 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Page 10508 Tail Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp assembly. 1. Pull the rear lamp assembly outward. 2. Disconnect the electrical connector and remove the rear lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery junction box (BJB) Fuse 5 (20 A) ^ BJB Fuse 19 (10 A) ^ BJB Fuse 2O (10 A) ^ BJB Fuse 101 (30 A) ^ BJB Fuse 108 (30 A) ^ Central junction box (CJB) Fuse 23 (10 A) ^ CJB Fuse 13 (10 A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10513 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery junction box (BJB) Fuse 5 (20 A) ^ BJB Fuse 19 (10 A) ^ BJB Fuse 2O (10 A) ^ BJB Fuse 101 (30 A) ^ BJB Fuse 108 (30 A) ^ Central junction box (CJB) Fuse 23 (10 A) ^ CJB Fuse 13 (10 A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10514 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10515 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10516 AB1 - AB2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10517 AC1 - AC2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10518 AC3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10519 AD1 - AD2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10520 AD3 AE Trailer Parking Lamps Inop Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10521 AE1 - AE2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10522 AE3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10523 AE4 - AE5 AF Trailer Lamp Are Inop-Trailer Reversing Lamps Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10524 AF1 - AF2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10525 AF3 - AF4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10526 AF5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10527 AG1 - AG2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10528 AG3 - AG4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10529 AH1 - AH2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10530 AH3 - AH5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10531 73 Digital Multimeter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Trailer Lighting Relay: Testing and Inspection Trailer Tow Running Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 10536 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 10537 Trailer Lighting Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 10538 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10548 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10549 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10550 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10551 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10552 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10553 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10554 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10555 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10556 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10557 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10558 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10559 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10565 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10566 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10567 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10568 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10569 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10570 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10571 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10572 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10573 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10574 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10575 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10576 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 10580 Turn Signal Flasher: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 10581 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Testing and Inspection Turn Signal Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10588 Turn Signal Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10591 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10592 Turn Signal Switch: Diagnostic Trouble Code Descriptions GEM Diagnostic Trouble Code Index Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10593 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10594 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10595 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10596 Part 5 Of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10597 Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10598 Turn Signal Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10599 Turn Signal Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: check that the program card is properly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT9 14, CKT9 15 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, diagnose the Module Communication Network. - NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.See: Pinpoint Tests/Test A: No Communication With The Module-GEM - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10600 diagnostics.See: Diagnostic Trouble Code Descriptions/GEM Diagnostic Trouble Code Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.See: Symptom Related Diagnostic Procedures GEM Diagnostic Trouble Code Index Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10601 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10602 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10603 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10604 Part 5 Of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10605 Part 1 Of 2 Part 2 Of 2 Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10606 Test A: No Communication With The Module-GEM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10607 Test A1 - A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10608 Test A3 - A4 Test A5 Test B: Unable To Enter Self-Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10609 Test B1 Test C: The Ignition Switch Is Inoperative Test C1 Test D: No Power In ACC Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10610 Test D1 Test E: No Power In RUN Test E1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10611 Test E1 - E2 Test F: No Power In START Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10612 Test F1 - F2 Component Tests and General Diagnostics Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10613 Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10614 Pinout Values and Diagnostic Parameters Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10615 Part 1 Of 3 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10616 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 10617 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 10618 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 10619 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Underhood Lamp: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10624 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Description and Operation Heated Glass Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Description and Operation > Page 10630 Heated Glass Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10634 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10635 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10636 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 10640 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering column opening cover. NOTICE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. 4. Remove the instrument panel finish panel. 1. Remove the panel bolts. 2. Remove the instrument panel finish panel. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 10641 6. Remove the rear window defrost switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10646 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10647 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10648 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10649 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10650 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Description and Operation Heated Glass Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Description and Operation > Page 10655 Heated Glass Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10660 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10661 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Description and Operation Power Window Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Description and Operation > Page 10665 Power Window Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > One Touch Down Relay Power Window Relay: Locations One Touch Down Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > One Touch Down Relay > Page 10670 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > One Touch Down Relay > Page 10671 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay Power Window Relay: Testing and Inspection One Touch Down Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 10674 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 10675 Power Window Relay: Testing and Inspection Vent Window/Roof Opening Panel Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 10676 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 10681 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering column opening cover. NOTICE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. 4. Remove the instrument panel finish panel. 1. Remove the panel bolts. 2. Remove the instrument panel finish panel. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 10682 6. Remove the rear window defrost switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 10687 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 10688 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 10689 Power Window Switch: Diagrams Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 10690 Power Window Switch: Description and Operation The window regulator control switch: - is located on each door trim panel. - may be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - includes a "double detent" feature. - can manually lower the driver side window when the master control is depressed halfway (first detent). - will completely lower the driver side window when the master control is fully depressed and then released (second detent). - can lock out passenger front and rear control switches. The rear quarter glass regulator control switches: - Are located in the overhead console. - May be used to open and close the RH or LH rear quarter windows. - Stop the rear quarter glass in any position when released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front Power Window Switch: Testing and Inspection Left Front Component Testing Procedure (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10693 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10694 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10695 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10696 Power Window Switch: Testing and Inspection Rear Power Window Control Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10697 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10698 Power Window Switch: Testing and Inspection Right Front Power Window Switch Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10699 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Description and Operation Power Window Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Description and Operation > Page 10704 Power Window Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications Power Window Motor: Specifications Power Window Motor Bolts 50-81 in.lb Rear Quarter Glass Motor Nuts 67.8-92.7 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor Power Window Motor: Service and Repair Rear Door Window Motor Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 10710 7. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator assembly. 8. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counter balance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 10711 Power Window Motor: Service and Repair Rear Quarter Window Motor REMOVAL 1. Remove the quarter trim panel. 2. Unclip the quarter window regulator from the quarter window. 3. Remove the rear quarter glass motor. 1. Disconnect the electrical connector. 2. Remove the nuts and the rear quarter glass motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 10712 Power Window Motor: Service and Repair Front Door Window Motor Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 10713 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator assembly. 8. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Rear Door Window Motor > Page 10714 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > One Touch Down Relay Power Window Relay: Locations One Touch Down Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > One Touch Down Relay > Page 10719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > One Touch Down Relay > Page 10720 RPO Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay Power Window Relay: Testing and Inspection One Touch Down Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 10723 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 10724 Power Window Relay: Testing and Inspection Vent Window/Roof Opening Panel Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > One Touch Down Relay > Page 10725 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 10730 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 10731 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 10732 Power Window Switch: Diagrams Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 10733 Power Window Switch: Description and Operation The window regulator control switch: - is located on each door trim panel. - may be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - includes a "double detent" feature. - can manually lower the driver side window when the master control is depressed halfway (first detent). - will completely lower the driver side window when the master control is fully depressed and then released (second detent). - can lock out passenger front and rear control switches. The rear quarter glass regulator control switches: - Are located in the overhead console. - May be used to open and close the RH or LH rear quarter windows. - Stop the rear quarter glass in any position when released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front Power Window Switch: Testing and Inspection Left Front Component Testing Procedure (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10736 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10737 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10738 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10739 Power Window Switch: Testing and Inspection Rear Power Window Control Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10740 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10741 Power Window Switch: Testing and Inspection Right Front Power Window Switch Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Front > Page 10742 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Lower the window glass to access the two window glass to regulator nuts. 5. Remove the inside glass weatherstrip. 6. Remove the front door rear glass channel bolt and position the channel aside. 7. Remove the window glass to regulator nuts. 8. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 10747 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Disconnect the rear window defrost grid electrical connector. 2. Remove the liftgate trim panels. 3. Disconnect the liftgate window glass support. 1. Remove the E-clip. 2. Remove the pin. 3. Disconnect the support. NOTE: Have an assistant hold the liftgate window glass. 4. Remove the liftgate window glass. 1. Remove the four bolts (two each side) 2. Remove the liftgate window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10751 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed Quarter Window Glass: Service and Repair Fixed REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. 1. Remove the nuts. 2. Push the rear quarter window glass outward to release the foam butyl seal. NOTE: Have an assistant hold the rear quarter window glass. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm Foam Butyl (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1. Position the rear quarter window glass. 2. Install quarter window glass nuts. NOTE: Loosely install all the nuts before tightening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 10756 3. Install the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 10757 Quarter Window Glass: Service and Repair Vented REMOVAL 1. Remove the quarter trim panel. 2. Remove the C-pillar trim panel. 3. If equipped, on the RH quarter window glass disconnect the portable cellular phone antenna base cable. 4. If equipped, cut the two-way tape holding the portable cellular phone antenna base to the glass. 5. If equipped, on the RH quarter window glass, remove the portable cellular phone antenna base. CAUTION: To avoid damage to the glass, do not pry the vehicle portable cellular phone antenna base when removing. 6. Remove the D-pillar trim panel. 7. Unclip the quarter window regulator from the quarter window. - If required, remove the quarter window regulator bracket bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 10758 8. Remove the quarter window glass. 1. Remove the nuts. 2. Remove the quarter window glass. - If required, remove the quarter window glass hinge bolts. NOTE: Have an assistant hold the rear quarter window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 10759 1. To Install, reverse the removal procedure. NOTE: The inside and outside portable cellular phone antenna base must be carefully and accurately aligned. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Remove the inside glass weatherstrip. 5. Remove the rear door glass channel lower bolt. 6. Remove the rear door fixed vent screw. 7. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 10763 8. Remove the window glass to regulator nuts. 9. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair For further information regarding this component please refer to Power Window Motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Quarter Window Regulator Bracket Bolt 18 in.lb Window Regulator Nuts 7.4-10 ft.lb Front Door Window Regulator Nuts 7.4-10 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: Customer Interest Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 10779 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 10780 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: All Technical Service Bulletins Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 10786 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 10787 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Page 10788 Window Track: Specifications Front Door Rear Glass Channel Bolt 7.4-10 ft.lb Rear Door Glass Channel Lower Bolt 91-123 in.lb Front Door Glass Run Channel Bolt 7.4-10 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 10797 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 10803 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10804 Windshield: Service and Repair Interior Auto Glass Cut-Out Knife Kit SPECIAL TOOL(S) REMOVAL 1. Remove the cowl top vent panels. 2. Remove the windshield side garnish mouldings. 3. Remove the inside rear view mirror. 4. Lower the front portion of the roof trim panel. 5. Remove the upper windshield weatherstrip. 6. Remove the LH and RH windshield mouldings. 7. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane. 8. Lubricate the Urethane Sealant with water to aid Interior Auto Glass Cut-Out Knife Kit while cutting. 9. Use Interior Auto Glass Cut-Out Knife Kit to cut the Urethane Sealant from the windshield glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10805 ^ Insert the blade into the urethane at the top middle and work toward the bottom corners. WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 10. Trim the excess Urethane Sealant from the outside edge of the windshield glass. 11. Remove the windshield glass. NOTE: Removing the windshield glass requires more than one technician. 12. Trim the remaining Urethane Sealant on the pinch weld to within specification. ^ The old urethane surface should be smooth and free of cuts and contamination. INSTALLATION CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond. 1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, or rust or foreign material that could cause glass damage. 2. Use the wool applicator to apply Urethane Metal Primer (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G314-B to any exposed metal on the pinch weld. 3. Apply 8 mm Foam Butyl (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to the pinch weld. 4. Remove excess Urethane Sealant from the windshield glass. 5. Clean the inside of the glass surface with an alcohol-free cleaner. 6. Apply Urethane Glass Prep (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C twice around the glass surface to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10806 be urethaned. NOTE: ^ Apply with deliberate strokes, making sure not to overlap applied area. ^ Wipe off the Urethane Glass Prep immediately after application because it flash dries. 7. Cut the urethane applicator tip to specification. 8. Apply a bead of Urethane Sealant (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G316-B to the pinch weld just outside the foam butyl dam. 9. Install the inside rear view mirror. 10. Position the windshield glass. 11. Install the upper windshield weatherstrip. 12. Paddle the excess Urethane Sealant from the two sides of the windshield glass. NOTE: Use one continuous stroke when removing the excess Urethane Sealant. 13. If necessary, remove excess Urethane Sealant from the outside surface of the windshield glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10807 14. Install the LH and RH windshield mouldings. 15. Install the roof trim panel. 16. Install the windshield side garnish mouldings. 17. Install the cowl top vent panels. 18. Install the windshield wiper pivot arms and adjust if necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Description and Operation Windshield Washer Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Description and Operation > Page 10813 Windshield Washer Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 10818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 10819 Windshield Washer Relay: Locations Rear Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 10820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay Windshield Washer Relay: Testing and Inspection Front Washer Pump Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 10823 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 10824 Windshield Washer Relay: Testing and Inspection Rear Washer Pump Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 10825 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 10829 Wiper Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay Wiper Relay: Locations Rear Wiper Up/Down Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10834 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10835 Wiper Relay: Locations Wiper High/Low Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10838 Wiper Relay: Locations Wiper Run/Park Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10839 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10840 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay Wiper Relay: Testing and Inspection Rear Wiper Down Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10843 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10844 Wiper Relay: Testing and Inspection Rear Wiper Up Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10845 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10846 Wiper Relay: Testing and Inspection Wiper High/Low Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10847 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10848 Wiper Relay: Testing and Inspection Wiper Run/Park Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10849 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10854 Windshield Washer Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10855 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10856 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10857 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10861 Wiper Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10862 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10863 Wiper Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10864 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Testing and Inspection Washer Fluid Level Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Description and Operation Windshield Washer Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Description and Operation > Page 10871 Windshield Washer Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect the jack handle from the windshield washer reservoir. 2. Disconnect the electrical connectors. 3. Remove the windshield washer reservoir screws. 4. Disconnect the windshield washer hoses. NOTICE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 10875 5. Remove the windshield washer reservoir. 6. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 10880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 10881 Windshield Washer Relay: Locations Rear Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 10882 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay Windshield Washer Relay: Testing and Inspection Front Washer Pump Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 10885 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 10886 Windshield Washer Relay: Testing and Inspection Rear Washer Pump Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Testing and Inspection > Front Washer Pump Relay > Page 10887 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Washer Reservoir Screws 42-48 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 10891 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect the jack handle from the windshield washer reservoir. 2. Disconnect the electrical connectors. 3. Remove the windshield washer reservoir screws. 4. Disconnect the windshield washer hoses. NOTICE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 10892 5. Remove the windshield washer reservoir. 6. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10896 Windshield Washer Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10897 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10898 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10899 5. Remove the upper and lower steering column shrouds. 1 Remove the three screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. 6. Remove the multi-function switch. 1 Remove the two screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Adjustment Wiper Arm: Specifications Adjustment Adjustment RH Wiper Blade Adjustment 65-93 mm LH Wiper Blade Adjustment 45-75 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Adjustment > Page 10904 Wiper Arm: Specifications Rear Wiper Stop Screws 7.2-10.7 in.lb Windshield Wiper Mounting Arm and Pivot Shaft Bolts 63-80 in.lb Windshield Wiper Pivot Arm Nuts 23-29 ft.lb Rear Window Wiper Pivot Arm Nut 113-154 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 10905 Wiper Arm: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1. Remove the pivot arm nut cover. 2. Remove the nut. 3. Remove and reposition the windshield wiper pivot arm. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Mounting Arm and Pivot Shaft Wiper Arm: Service and Repair Mounting Arm and Pivot Shaft REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the on position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch off. 4. Remove the windshield wiper pivot arm. 1. Remove the pivot arm nut cover. 2. Remove the nut. 3. Remove the windshield wiper pivot arm. 5. Raise and support the hood. 6. Remove the cowl grille seal. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. 7. Remove the LH cowl grille. 1. Remove the screw cover. 2. Remove the screws. 3. Remove the clips. 4. Remove the pin-type retainer. 5. Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Mounting Arm and Pivot Shaft > Page 10908 8. Remove the RH cowl grille. 1. Remove the screw cover. 2. Remove the screws. 3. Remove the clips. 4. Remove the pin-type retainer. 5. Remove the RH cowl grille. 9. Remove the mounting arm and pivot shaft. 1. Disconnect the electrical connector. 2. Remove the bolts. 3. Remove the mounting arm and pivot shaft. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Mounting Arm and Pivot Shaft > Page 10909 1. To install, reverse the removal procedure. NOTE: Adjust the pivot arms. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Mounting Arm and Pivot Shaft > Page 10910 Wiper Arm: Service and Repair Pivot Arm Front REMOVAL 1. Remove the windshield wiper pivot are. 1. Remove the pivot arm nut cover. 2. Remove the nut. 3. Remove the windshield wiper pivot arm. INSTALLATION 1. To install, reverse the removal procedure. ^ Adjust the windshield wiper pivot arms. Rear REMOVAL 1. Remove rear pivot arm. 1. Lift the pivot arm nut cover. 2. Remove the nut. 3. Remove the pivot arm. CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Mounting Arm and Pivot Shaft > Page 10911 INSTALLATION 1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle. Turn the rear wiper switch to off. NOTE: This step ensures that the wiper motor is in the park position. 2. Position the wiper blade outside the wiper arm stop. 3. Install the wiper pivot arm onto the wiper motor. ^ Tighten the retaining nut. 4. Cycle the wiper motor one time to allow the wiper arm to park on the wiper arm stop. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments Wiper Blade: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1. Remove the pivot arm nut cover. 2. Remove the nut. 3. Remove and reposition the windshield wiper pivot arm. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 10918 Wiper Control Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) For further information regarding this component please refer to General Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Windshield Wiper Motor Bolts 10-12 ft.lb Rear Window Wiper Motor Screws 80-107 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor REMOVAL 1. Remove the mounting arm and pivot shaft. 2. Disconnect the windshield wiper linkage. 1. Remove the bolt. 2. Disconnect the windshield wiper linkage. 3. Remove the windshield wiper motor. 1. Remove the bolts. 2. Remove the windshield wiper motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 10924 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 10925 Wiper Motor: Service and Repair Rear Wiper Motor REMOVAL 1. Remove the rear pivot arm. 2. Remove the upper liftgate trim panel. 3. Remove the liftgate assist strap. 1. Remove the screws. 2. Remove the liftgate assist strap. 4. Remove the lower liftgate trim panel. 5. Remove the liftgate watershield. 6. Remove the rear window wiper motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 10926 1. Disconnect the electrical connector. 2. Remove the three screws. 3. Remove the rear window wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the on position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch off. 4. Remove the windshield wiper pivot arm. 1. Remove the pivot arm nut cover. 2. Remove the nut. 3. Remove the windshield wiper pivot arm. 5. Raise and support the hood. 6. Remove the cowl grille seal. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. 7. Remove the LH cowl grille. 1. Remove the screw cover. 2. Remove the screws. 3. Remove the clips. 4. Remove the pin-type retainer. 5. Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Page 10930 8. Remove the RH cowl grille. 1. Remove the screw cover. 2. Remove the screws. 3. Remove the clips. 4. Remove the pin-type retainer. 5. Remove the RH cowl grille. 9. Remove the mounting arm and pivot shaft. 1. Disconnect the electrical connector. 2. Remove the bolts. 3. Remove the mounting arm and pivot shaft. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Page 10931 1. To install, reverse the removal procedure. NOTE: Adjust the pivot arms. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay Wiper Relay: Locations Rear Wiper Up/Down Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10936 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10937 Wiper Relay: Locations Wiper High/Low Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10938 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10939 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10940 Wiper Relay: Locations Wiper Run/Park Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10941 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up/Down Relay > Page 10942 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay Wiper Relay: Testing and Inspection Rear Wiper Down Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10945 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10946 Wiper Relay: Testing and Inspection Rear Wiper Up Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10947 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10948 Wiper Relay: Testing and Inspection Wiper High/Low Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10949 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10950 Wiper Relay: Testing and Inspection Wiper Run/Park Relay Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Rear Wiper Down Relay > Page 10951 Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation The steering column switches consist of the: - multifunction switch, which controls the: turn signal. - hazard flasher. - windshield wiper/washer. - rear wiper/washer. - headlamp dimmer/flash-to-pass. - ignition switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10955 Wiper Switch: Testing and Inspection Terminals Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10956 For additional testing, refer to Turn Signal Switch under Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN W (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10957 Wiper Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover.